Bobcat Loaders M444, M500, M600, 600, 600D, 610, M610, 611, 620 Repair Service Manuals
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Model:
Complete repair service manual with Electrical Wiring Diagrams for Bobcat M444, M500, M600, 600, 600D, 610, M610, 611, 620 Loaders, with all the technical information to maintain, diagnose, and repair like professional mechanics.
Bobcat Loaders M444, M500, M600, 600, 600D, 610, M610, 611, 620 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.
6509710 (3-97) - M444, M500, M600 Operation & Maintenance Manual.pdf
6545596 (1-87) - 500, 600, 610 Loader Operation & Maintenance Manual.pdf
6549746 (3-99) - 620 Operation & Maintenance Manual.pdf
6549846 (6-12) - 620 Service Manual.pdf
6549846 (9-75) - 620 Service Manual.pdf
6556099 (11-86) - 610 Operation & Maintenance Manual.pdf
6556100 (3-77) - 611 Operation & Maintenance Manual.pdf
6556276 (6-12) - 600, 600D, 610, 611 Service Manual.pdf
6556276 (6-87) - 600, 600D, 610, 611 Service Manual.pdf
6556520 (3-87) - 444, 500, 600 Service Manual Supplement.pdf
6556520 (6-12) - 444, 500, 600 Service Manual Supplement.pdf
6556602 - M444, M500, M600, M610 Service Manual.pdf
Supplement to 6556276 - 444, 500, 600 Service Manual Supplement.pdf
Total Pages: 1,232 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
6509710 (3-97) - M444, M500, M600 Operation & Maintenance Manual...1
OPERATOR SAFETY WARNINGS...3
CONTENTS...5
PICTORIAL CONTENTS...6
LOADER OPERATION...7
MOUNTING AND DISMOUNTING...7
THROTTLE CONTROL (on all machines except electric)...7
VARIABLE SPEED DRIVE CONTROL...7
HYDRAULIC CONTROL PEDALS...7
DIRECTIONAL CONTROL LEVERS...8
STARTING PROCEDURE...8
GENERATOR INDICATOR LIGHT...11
LEARNING TO OPERATE THE BOBCAT...13
ELECTRIC MOTOR OPERATION...13
BOB-TACH...14
FILLING THE BUCKET FROM A PILE...14
OPERATION HINTS...14
DIGGING WITH THE BUCKET...15
LEVELING AND BACKFILLING...15
COUNTERWEIGHTING...16
DUMPING THE BUCKET...16
TRANSPORTING THE BOBCAT...17
TRANSPORTING BY PICKUP...17
TRANSPORTING BY TRAILER...17
HOISTING THE BOBCAT...17
MAINTENANCE SAFETY...18
GENERAL MAINTENANCE...19
IMPORTANCE OF ROUTINE MAINTENANCE...19
TIRE INFLATION...19
TIRE ROTATION...19
TIRE REPLACEMENT...19
BOBCAT LUBRICATION POINTS...19
CHANGING AND ADDING HYDRAULIC OIL...19
DRAINING CONDENSATION...20
DESCRIPTION OF HYDRAULIC CIRCUIT...20
OIL FILTRATION...20
HYDRAULIC SYSTEM (M-600 Gasoline & LP Gas)...21
HYDRAULIC SYSTEM (M-44 & M-500)...21
HYDRAULIC SYSTEM (M-600 Diesel W/Deutz Engine)...22
HYDRAULIC SYSTEM (M-600 Electric & M-600 Diesel W/Petter Engine)...22
CHANGING HYHDRAULIC OIL & FILTER ELEMENT...23
SERVICE SCHEDULE ...24
GASOLINE & LP ENGINE SERVICE...25
CHANGING ENGINE OIL...25
OIL SPECIFICATIONS...25
ENGINE OIL FILTER...25
CRANKCASE BREATHER ASSEMBLY...25
ENGINE AIR CLEANER...25
AIR CLEANER INSPECTION...26
HEAVY DUTY AIR CLEANER...26
GASOLINE SPECIFICATIONS...27
GASOLINE PUMP (M-500 Only)...27
LP GAS...27
ENGINE COOLING SYSTEM...27
STARTER SERVICE...28
SPARK ARRESTOR MUFFLER (Optional)...28
ELECTRIC MOTOR SERVICE...29
PREVENTIVE MAINTENANCE...29
BEARING REPLACEMENT...29
BEARING LUBBRICATION...29
RELUBRICATION PERIOD...29
ENGINE CABLE REPLACEMENT...31
REEL SPRING REPLACEMENT...31
CABLE REEL LUBRICATION...32
SPRING LUBRICATION...32
CABLE SWIVEL...32
DEUTZ DIESEL ENGINE SERVICE...33
CHANGING ENGINE OIL...33
OIL SPECIFICATIONS...33
ENGINE OIL FILTER...33
CRANKCASE BREATHER...33
ENGINE AIR CLEANER...34
AIR CLEANER INSPECTION...34
OIL BATH AIR CLEANER...35
ENGINE FUEL FILTER...35
ENGINE FUEL...35
ENGINE COOLING SYSTEM...35
STARTER SERVICE...35
WATER SCRUBBER MUFFLER (M-600 Diesel)...35
PETTER DIESEL ENGINE SERVICE...37
CHANGING ENGINE OIL...37
OIL SPECIFICATIONS...37
ENGINE OIL FILTER...37
ENGINE AIR CLEANER...37
AIR CLEANER INSPECTION...37
FARR HEAVY DUTY AIR CLEANER...38
ENGINE FUEL FILTER...38
ENGINE FUEL...38
ENGINE COOLING SYSTEM...39
STARTER SERVICE...39
ADJUSTMENTS...41
DIRECTIONAL CONTROL CLUTCHES...41
VARIABLE SPEED DRIVE...42
DRIVE BELT REPLACEMENT (One Piece Jackshaft)...42
DRIVE BELT REPLACEMEN (Split Jackshaft)...43
DRIVE SHEAVE ALIGNMENT (Spring Loaded)...43
DRIVE CHAIN ADJUSTMENT...43
CONTROL PEDAL LINKAGE ADJUSTMENT...45
UNDERGROUND OPERATION...47
TROUBLESHOOTING...49
TROUBLESHOOTING THE ENGINE...49
TROUBLESHOOTING THE HYDRAULIC SYSTEM...51
TROUBLESHOOTING THE DRIVE SYSTEM...53
TROUBLESHOOTING THE FRAME COMPONENTS...55
LOADER SPECIFICATIONS (Gasoline & LP Gas)...56
OPERATIONAL & PERFORMANCE...56
ENGINE...57
LOADER HYDRAULICS...57
ELECTRICAL...57
POWER TRAIN...57
CAPACITIES...57
COUNTERWEIGHT...57
MACHINE WEIGHT (Less Bucket)...57
LOADER SPECIFICATIONS (Diesel)...58
OPERATIONAL & PERFORMANCE...58
ENGINE...59
LOADER HYDRAULICS...59
ELECTRICAL...59
POWER TRAIN...59
CAPACITIES...59
TIRES...59
COUNTERWEIGHT...59
MACHINE WEIGHT (Less Bucket)...59
LOADER SPECIFICATIONS (Electric)...60
OPERATIONAL & PERFORMANCE...60
MOTOR...60
LOADER HYDRAULICS...60
POWER TRAIN...60
CAPACITIES...60
TIRES...60
COUNTERWEIGHT...60
MACHINE WEIGHT (Less Bucket)...60
MAJOR PARTS INDEX...61
MAIN FRAME PARTS...62
DRIVE SYSTEM...63
ENGINE & ATTACHING PARTS...64
ELECTRICAL MOTOR, REEL & MAST...69
GENERATOR ELECTRICAL CIRCUIT...70
ALTERNATOR ELECTRICAL CIRCUIT...71
MAIN FRAME HYDRAULIC CIRCUITRY...72
LOADER HYDRAULICS...73
6545596 (1-87) - 500, 600, 610 Loader Operation & Maintenance Manual...75
OPERATOR SAFETY WARNINGS...77
CONTENTS...79
GENERAL OPERATION INSTRUCTIONS...81
INTRODUCTION...83
MOUNTING AND DISMOUNTING...83
INSTRUMENTATION...83
ENGINE CONTROLS...84
DRIVE CONTROLS...84
LOADER HYDRAULIC CONTROLS...84
PRE-START CHECK...85
STARTING PROCEDURE (All Loader Models)...85
NEW ENGINE OPERATION...86
ELECTRIC MOTOR STARTING...86
SHUT-DOWN PROCEDURE...87
OPERATING THE BUCKET...87
ELECTRIC MOTOR OPERATION...87
BOB-TACH SYSTEM...88
BUCKET SIZE...88
COUNTERWEIGHTING...88
OPERATING BOBCAT WITH BUCKET...89
OPERATION HINTS...89
UNLOADING BOXCAR WITH ELECTRIC BOBCAT...90
DUMPING LOAD INTO TRUCK BOX...90
LEVELING AND BACKFILLING WITH BUCKET...91
UNDERGROUND OPERATION...91
TRANSPORTING BY TRUCK...93
TRANSPORTING BY TRAILIER...93
TOWING THE BOBCAT...93
HOISTING THE BOBCAT (With Optional Lift Bail)...93
PREVENTIVE MAINTENANCE SERVICE SCHEDULE...94
SERVICE AND MAINTENANCE...97
IMPORTANCE OF ROUTINE MAINTENANCE...99
TIRES...99
TIRE MAINTENANCE...99
BOBCAT LUBRICATION POINTS...99
CHANGING AND ADDING HYDRAULIC FLUID...100
DRAINING CONDENSATION...100
DIRECTIONAL CONTROL CLUTHES...100
VARIABLE SPEED DRIVE...101
DRIVE BELT REPLACEMENT (One Piece Jackshaft)...101
DRIVE BELT REPLACEMENT (Split Jackshaft)...102
DRIVEN SHEAVE ALIGNMENT (Spring Loaded)...102
DRIVE CHAIN ADJUSTMENT...103
DESCRIPTION OF HYDRAULIC CIRCUIT...105
OIL FILTRATION...105
HYDRAULIC FLUID FILTER REPLACEMENT...106
HYDRAULIC FLUID LEAKS...106
HYDRAULIC CYLINDER MAINTENANCE...106
QUICK COUPLERS...107
CONTROL PEDAL LINKAGE ADJUSTMENT...107
ENGINE AIR CLEANER...108
AIR CLEANER INSPECTION...108
HEAVY DUTY AIR CLEANER...108
AIR FILTER SERVICE PRECAUTIONS...108
OIL BATH AIR CLEANER (Deutz Only)...109
GASOLINE SPECIFICATIONS (Kohler And Wisconsin)...109
GASOLINE PUMP (Kohler Only)...109
LP GAS...109
FUELl SYSTEM SERVICE (Deutz Diesel)...110
ENGINE FUEL (Deutz Diesel)...110
AIR VENTING THE FUEL SYSTEM...110
FUEL SPECIFICATIONS (Petter Diesel)...110
ENGINE FUEL FILTER (Petter Diesel)...110
WATER SCRUBBER MUFFLER (M-600 Diesel)...111
SPARK ARRESTOR MUFFLER (Optional)...111
CHANGING ENGINE OIL (Kohler And Wisconsin)...112
OIL SPECIFICATIONS (Kohler And Wisconsin)...112
ENGINE OIL FILTER (Kohler And Wisconsin)...112
CRANKCASE BREATHER ASSEMBLY (Kohler Engine)...112
CRANKCASE BREATHER ASSEMBLY (Wisconsin Engine)...112
CHANGING ENGINE OIL (Deutz Engine)...112
OIL SPECIFICATIONS (Deutz Diesel)...112
ENGINE OIL FILTER (Deutz Diesel)...113
CRANKCASE BREATHER (Deutz Diesel)...113
CHANGING ENGINE OIL (Petter Diesel)...113
OIL SPECIFICATION (Petter Diesel)...114
ENGINE OIL FILTER (Petter Diesel)...114
ENGINE COOLING SYSTEM...114
HIGH TEMPERATURE SAFETY SWITCHES...114
STARTER SERVICE...114
ELECTRICAL SYSTEM...115
ELECTRIC MOTOR SERVICE...116
PREVENTIVE MAINTENANCE...116
BEARING LUBRICATION...116
RELUBRICATION PERIOD...116
ELECTRIC CABLE REPLACEMENT...116
REEL SPRING REPLACEMENT...118
CABLE REEL LUBRICATION...118
SPRING LUBRICATION...118
TROUBLESHOOTING...119
ENGINE PROBLEM...121
DRIVE PROBLEM...124
HYDRAULIC PROBLEM...126
SPECIFICATIONS...129
OPERATIONAL & PERFORMANCE...132
ENGINE...132
LOADER HYDRAULICS...132
ELECTRICAL...132
POWER TRAIN...132
CAPACITIES...132
TIRES...132
COUNTERWEIGHT...132
MACHINE WEIGHT (Less Attachment)...132
MAJOR PARTS IDENTIFICATION...135
MAIN FRAME PARTS...137
DRIVE SYSTEM...138
KOHLER ENGINE & ATTACHING PARTS...139
WISCONSIN ENGINE & ATTACHING PARTS...140
DEUTZ ENGINE & ATTACHING PARTS...141
PETTER ENGINE & ATTACHING PARTS...142
ELECTRIC MOTOR, REEL & MAST...143
ELECTRICAL CIRCUITRY...144
MAIN FRAME HYDRAULIC CIRCUITRY...145
LOADER HYDRAULICS...146
WARRANTY...147
6549746 (3-99) - 620 Operation & Maintenance Manual...149
WARNINGS...150
FOREWORD...151
CONTENTS...151
620 BOBCAT LOADER PICTORIAL PARTS...152
OPERATING INSTRUCTIONS...153
OPERATING INSTRUCTIONS...155
SAFETY...155
MOUNTING & DISMOUNTING...155
CONTROLS...155
PRE-STSRTING INSPECTION...157
STARTING PROCEDURE...157
NORMAL STARTING CONDITION...157
COLD WEATHER STARTING CONDITIONS...158
BUCKET SIZE...158
TO OPERATE THE BOBCAT...158
FILLING THE BUCKET...159
OPERATION HINTS...159
DIGGING WITH THE BUCKET...159
LEVELING AND BACKFILLING...160
DUMPING THE BUCKET...160
TOWING...160
TRANSPORTING BY PICKUP...160
TRANSPORTING BY TRAILER...160
PREVENTIVE MAINTENANCE...161
SERVICE & MAINTENANCE...162
SERVICE SCHEDULE...163
ROPS ENCLOSURE...164
Tilting The ROPS...164
BOB-TACH...164
PIVOT PINS...164
WHEEL RORQUING...164
TIRE MAINTENANCE...164
TIRE ROTATION...165
TIRE REPLACEMENT...165
LUBRICATION...165
ENGINE OIL SPECIFICATIONS...165
CHANGING OIL AND FILTER...166
TO CHANGE OIL FILTER ELEMENT...166
ENGINE AIR INLET SYSTEM (AIR CLEANER)...166
ENGINE COOLING SYSTEM...167
FUEL SERVICING...168
CONDENSATION IN THE FUEL TANK...168
ELECTRICAL SYSTEM...169
HYDRAULIC SYSTEM...170
TRANSMISSION FLUID FILTERS...170
HYDRAULIC/HYDROSTATIC TRANSMISSION FLUID...171
CHECKING AND ADDING FLUID...171
DRAINING THE FLUID RESERVOIR...171
QUICK COUPLERS...172
HYDRAULIC SYSTEM LEAKS...172
HYDRAULIC CYLINDER MAINTENANCE...172
HYDRAULIC CYLINDER INSPECTION...172
HYDROSTATIC SYSTEM...173
MAINTENANCE OF HYDROSTATIC TRANSMISSION...173
REPLACEMENT OF 10 MICRON FILTER...173
AIR IN SYSTEM...174
OVERHEATING...174
CONTROL LINKAGE...174
MECHANICAL TRANSMISSION (CHAIN REDUCTION)...174
TROUBLESHOOTING...175
TROUBLESHOOTING THE ENGINE...177
TROUBLESHOOTING THE DRIVE SYSTEM...178
TROUBLESHOOTING THE HYDRAULIC SYSTEM...179
MAJOR PARTS...181
MAIN FRAME PARTS...183
HYDRAULIC SYSTEM...184
WISCONSIN ENGINE PARTS...185
ELECTRICAL SYSTEM...186
HYDROSTATIC SYSTEM...187
DRIVE SYSTEM...188
GENERAL INFORMATION...189
LOADER ACCESSORIES...191
FRONT & REAR LIGHTS...191
FLASHER LIGHTS...191
WINDSHIELD WIPER...191
BACKUP ALARM...191
OPERATIONAL & PERFORMANCE...192
ENGINE...192
LOADER HYDRAULICS...192
ELECTRICAL...192
POWER TRAIN...192
CAPACITIES...192
TIRES...192
MACHINE WEIGHT...192
DELIVERY REPORT...193
50-HOUR INSPECTION...193
PRE-DELIVERY INSPECTION...193
LOADER TORQUES...194
ENGINE TORQUES...194
WARRANTY...195
6549846 (6-12) - 620 Service Manual...197
MAINTENANCE SAFETY...199
INTRODUCTION...201
SYMBOLS...201
SERIAL NUMBER IDENTIFICATION...201
LOADER SERIAL NUMBER...201
ENGINE SERIAL NUMBER...201
PRE-DELIVERY INSPECTION...202
30 HOUR INSPECTION...202
PREVENTIVE MAINTENANCE...203
SERVICE SCHEDULE...203
AIR CLEANER SERVICE...204
ENGINE FUEL SYSTEM...204
ENGINE OIL AND FILTER REPLACEMENT...204
CLEANING ENGINE COOLING SYSTEM...205
TIRES...205
LOADER LUBRICATION...206
SEAT AND SEAT BELTS...206
ROLL-OVER PROTECTIVE STRUCTURE...206
CONTROLS...207
CHOKE LINKAGE ADJUSTMENT...207
THROTTLE ADJUSTMENT...207
ELECTRICAL SYSTEM...208
CHAIN ADJUSTMENT...208
BRAKE ADJUSTMENT...208
HYDRAULIC / HYDROSTATIC SYSTEM SERVICE...209
Hydraulic / Hydrostatic Transmission Fluid...209
checking, Adding Or Changing Fluid...209
Water In Reservoir...209
Replacement Of Section (25 Micron) Filter...209
Replacement Of 10 Micron Filter...210
LOADER HYDRAULIC SYSTEM...211
OPERATION OF THE HYDRAULIC SYSTEM...213
GENERAL INFORMATION...213
Clean Area...213
Air Leaks...213
Tubelines, Hoses & Fittings...213
37° Flare Connections...213
Straight Thread O-Ring Connections...214
Pipe Thread Connections...214
Tubelines & Hoses...214
TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM...215
CHARGING THE VANE PUMP AND CHECKING FOR SUCTION LEAKS...216
Charging The Pump When No Source Of Air Pressure Is Available...217
Another Method To Check The System For Air Leaks...217
CHECKING RELEASE PRESSURE...218
Machines Without Auxiliary Hydraulics...218
Machines With Auxiliary Hydraulics...218
CHECKING THE CONDITION OF THE VANE PUMP...218
Checking Vane Pump...218
VANE PUMP SERVICE...219
To Remove The Vane Pump...219
Disassembly...219
Inspection And Service...219
Assembly...220
To Install The Vane Pump...220
CONTROL VALVE AND HYDRAULIC CYLINDER CHECKS...220
Checking The Lift Cylinders...220
Checking The Tilt Cylinders...220
HYDRAULIC CYLINDER REPAIR...221
Removing Cylinders...221
To Disassemble A Hydraulic Lift Or Tilt Cylinder...221
To Replace The Cylinder Seals...221
To Assemble The Hydraulic Cylinder...222
CONTROL VALVE REPAIR...222
Relief Valve Repair...222
To Remove The Control Valve...222
To Disassemble The Control Valve...223
To Repair The Float Detent Of The Lift Spool...224
To Assemble The Detent Assembly...224
Inspection, Repair And Assembly Of Control Valve...224
HYDROSTATIC DRIVE SYSTEM...225
HYDROSTATIC DRIVE SYSTEM...227
Circuit Description...227
TROUBLESHOOTING CHART...228
PROBLEM ANALYSIS CHARTS...229
STEERING LINKAGE...232
Adjustment Of The Steering Linkage...232
To Remove The Steering Lever Assembly...233
CHECKING THE HYDROSTATIC SYSTEM...233
Charge Pressure Check (Levers In Neutral)...234
Charge Pressure Check (Levers Engaged)...234
CHECK VALVE SERVICE...234
Checking The Check Valve...234
To Remove The Check Valve...234
REPLENISHING VALVES...235
Checking The Replenishing Valves...235
HYDROSTATIC MOTOR REPLACEMENT...235
REPLACEMENT OF TRANSMISSION PUMP ASSEMBLY...236
Removal...236
HYDROSTATIC TRANSMISSION RECONDITIONING PROCEDURE...237
Transmission Pump...237
Disassembly Of Pumps And Motors...237
To Disassemble Pump Or Motor...237
Inspection Of Pump Or Motor...240
Assembly Of Pump Or Motor...240
START-UP AFTER REPAIR...241
MECHANICAL FINAL DRIVE SYSTEM...243
FINAL DRIVE SYSTEM (MECHANICAL)...245
REPAIR AND REPLACEMENT OF BRAKE ASSEMBLY...245
Removal Of Caliper Assembly...245
Removal Of Lever Assembly...245
Linkage Rod Assembly...245
FINAL DRIVE...246
CHAIN REMOVAL AND INSTALLATION...246
To Remove And Install Chains...246
Primary Drive Chain Removal...246
To Install The Primary Drive Chain...247
Secondary Drive Chain Removal...247
To Install The Secondary Drive Chain...247
Final Drive Chain Removal...247
To Install The Final Drive Chain...248
MOTOR SPROCKET SERVICE...248
Motor Sprocket Removal (Machines Without Brakes)...248
To Install The Motor Sprocket (Machines Without Brakes)...248
Motor Sprocket Removal (Machines With Brakes)...248
To Install The Motor Sprocket (Machines With Brakes)...249
UPPER JACKSHAFT SERVICE...249
To Remove The Upper Jackshaft Sprocket...249
Assembly...250
To Install Tjhe Upper Jackshaft Sprocket...250
IDLER SPROCKET SERVICE (PRIMARY AND SECONDARY)...250
SERVICING LOWER JACKSHAFT SPROCKET...250
To Remove The Lower Jackshaft Assembly...250
To Install The Lower Jackshaft Assembly...251
Lower Jackshaft Bearing Replacement...251
FINAL DRIVE TIGHTENER SERVICE...251
To Remove Final Drive Tightener...251
To Remove Final Drive Idler Sprocket And Bearing...252
To Install Final Drive Idler Bearing...252
WHEEL AND AXLE REPAIR...252
To Remove Axle Assembly...252
To Install New Axle Bearing And Seal...253
To Install The Axle...254
MAIN FRAME...255
THE BOB-TACH...257
Removal And Replacement Of Bob-Tach...257
LOADER LIFT ARM ASSEMBLY...257
Replacement Of Lift Arms...257
GRILL ASSEMBLY...258
FUEL TANK...258
Fuel Tank Removal...258
ELECTRICAL SYSTEM...259
ELECTRICAL CIRCUITRY...261
PROBLEM ANALYSIS CHARTS...261
GENERATOR DRIVE BELT...263
TO CHECK WIRING...263
TO CHECK GENERATOR OUTPUT...263
TO CHECK THE REGULATOR...264
GENERATOR SERVICE...264
Removal ...264
Disassembly...264
To Check Rotor...264
To Check Stator...264
To Check Diode Trio...265
To Check Rectifier...265
Assembly...265
STARTER SERVICE...266
To Check The Starter...266
To Remove The Starter...266
Disassembly And Inspection...266
Assembly...266
WISCONSIN ENGINE SERVICE...267
TROUBLESHOOTING THE ENGINE...269
ENGINE IGNITION SYSTEM...270
Distributor Maintenance...270
Timing Procedure...270
Spark Plug...270
High Temperature Safety Switches...271
CARBURETOR SERVICE...271
Adjustment...271
Carburetor Removal & Disassembly...271
To remove The Throttle Body Assembly...271
To Disassemble The Throttle Body...271
To Disassemble The Fuel Bowl...272
To Assemble The Fuel Bowl And Air Intake Assembly...272
To Assemble The Throttle Body...273
To Assemble The Fuel Bowl To The Throttle Body...273
LP CARBURETOR SERVICE...274
To remove The LP Carburetor From The Engine...274
Disassembly...274
Cleaning And Inspection...274
Assembly...275
VAPORIZER - PRIMARY REGULATOR SERVICE...276
Disassembling The Vaporizer...277
Assembling The Vaporizer...277
Adjusting The Vaporizer...278
LP FUEL FILTER LOCK-OFF...278
ENGINE SERVICE...279
Engine Removal...279
Disassembly Of Flywheel...280
Air Shrouding...280
Carburetor And Manifolds...280
Cylinder Head...280
Gear Cover...281
Camshaft Gear...281
Idler Gear And Shaft...281
Oil Pan...281
Oil Pump...281
Pistons And Connecting Rods...281
Piston Rings...282
Cylinder Blocks...282
Valves And Seat Inserts...283
Crankshaft...283
Camshaft...283
Valve Tappets...283
Govenor Adjustment...284
Storage Of Engines...284
Returning Engine To Service...284
Returning Compression To Engine...284
SPECIFICATIONS, SPECIAL TOOLS AND ETC...285
FUEL SPECIFICATIONS...287
ENGINE OIL SPECIFICATIONS...287
HYDRAULIC / HYDROSTATIC TRANSMISSION FLUID...287
FITS, CLEARANCE AND ADJUSTMENTS...288
Engine...288
Hydraulic / Hydrostatic System...288
SPECIAL TOOLS...288
Main Frame & Hydraulics...288
Wisconsin Engine...289
Hydrostatic System...289
LP Carburetor...289
TORQUE SPECIFICATIONS...289
Loader Torques...289
EngineTorques...289
DECIMAL AND MILLIMETER EQUIVALENTS...290
U.S. TO METRIC CONVERSION...290
LOADER SPECIFICATIONS...291
Operational & Performance...291
Engine...291
Loader Hydraulics...291
Electrical...291
Power Train...291
Capacities...291
Tires...291
Machine Weight...291
ALPHABETICAL INDEX...293
SMR...297
620-1...297
6549846 (9-75) - 620 Service Manual...299
MAINTENANCE SAFETY...301
INTRODUCTION...303
SYMBOLS...303
SERIAL NUMBER IDENTIFICATION...303
LOADER SERIAL NUMBER...303
ENGINE SERIAL NUMBER...303
PRE-DELIVERY INSPECTION...304
30 HOUR INSPECTION...304
PREVENTIVE MAINTENANCE...305
SERVICE SCHEDULE...305
AIR CLEANER SERVICE...306
ENGINE FUEL SYSTEM...306
ENGINE OIL AND FILTER REPLACEMENT...306
CLEANING ENGINE COOLING SYSTEM...307
TIRES...307
LOADER LUBRICATION...308
SEAT AND SEAT BELTS...308
ROLL-OVER PROTECTIVE STRUCTURE...308
CONTROLS...309
CHOKE LINKAGE ADJUSTMENT...309
THROTTLE ADJUSTMENT...309
ELECTRICAL SYSTEM...310
CHAIN ADJUSTMENT...310
BRAKE ADJUSTMENT...310
HYDRAULIC / HYDROSTATIC SYSTEM SERVICE...311
Hydraulic / Hydrostatic Transmission Fluid...311
checking, Adding Or Changing Fluid...311
Water In Reservoir...311
Replacement Of Section (25 Micron) Filter...311
Replacement Of 10 Micron Filter...312
LOADER HYDRAULIC SYSTEM...313
OPERATION OF THE HYDRAULIC SYSTEM...315
GENERAL INFORMATION...315
Clean Area...315
Air Leaks...315
Tubelines, Hoses & Fittings...315
37° Flare Connections...315
Straight Thread O-Ring Connections...316
Pipe Thread Connections...316
Tubelines & Hoses...316
TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM...317
CHARGING THE VANE PUMP AND CHECKING FOR SUCTION LEAKS...318
Charging The Pump When No Source Of Air Pressure Is Available...319
Another Method To Check The System For Air Leaks...319
CHECKING RELEASE PRESSURE...320
Machines Without Auxiliary Hydraulics...320
Machines With Auxiliary Hydraulics...320
CHECKING THE CONDITION OF THE VANE PUMP...320
Checking Vane Pump...320
VANE PUMP SERVICE...321
To Remove The Vane Pump...321
Disassembly...321
Inspection And Service...321
Assembly...322
To Install The Vane Pump...322
CONTROL VALVE AND HYDRAULIC CYLINDER CHECKS...322
Checking The Lift Cylinders...322
Checking The Tilt Cylinders...322
HYDRAULIC CYLINDER REPAIR...323
Removing Cylinders...323
To Disassemble A Hydraulic Lift Or Tilt Cylinder...323
To Replace The Cylinder Seals...323
To Assemble The Hydraulic Cylinder...324
CONTROL VALVE REPAIR...324
Relief Valve Repair...324
To Remove The Control Valve...324
To Disassemble The Control Valve...325
To Repair The Float Detent Of The Lift Spool...326
To Assemble The Detent Assembly...326
Inspection, Repair And Assembly Of Control Valve...326
HYDROSTATIC DRIVE SYSTEM...327
HYDROSTATIC DRIVE SYSTEM...329
Circuit Description...329
TROUBLESHOOTING CHART...330
PROBLEM ANALYSIS CHARTS...331
STEERING LINKAGE...334
Adjustment Of The Steering Linkage...334
To Remove The Steering Lever Assembly...335
CHECKING THE HYDROSTATIC SYSTEM...335
Charge Pressure Check (Levers In Neutral)...336
Charge Pressure Check (Levers Engaged)...336
CHECK VALVE SERVICE...336
Checking The Check Valve...336
To Remove The Check Valve...336
REPLENISHING VALVES...337
Checking The Replenishing Valves...337
HYDROSTATIC MOTOR REPLACEMENT...337
REPLACEMENT OF TRANSMISSION PUMP ASSEMBLY...338
Removal...338
HYDROSTATIC TRANSMISSION RECONDITIONING PROCEDURE...339
Transmission Pump...339
Disassembly Of Pumps And Motors...339
To Disassemble Pump Or Motor...339
Inspection Of Pump Or Motor...342
Assembly Of Pump Or Motor...342
START-UP AFTER REPAIR...343
MECHANICAL FINAL DRIVE SYSTEM...345
FINAL DRIVE SYSTEM (MECHANICAL)...347
REPAIR AND REPLACEMENT OF BRAKE ASSEMBLY...347
Removal Of Caliper Assembly...347
Removal Of Lever Assembly...347
Linkage Rod Assembly...347
FINAL DRIVE...348
CHAIN REMOVAL AND INSTALLATION...348
To Remove And Install Chains...348
Primary Drive Chain Removal...348
To Install The Primary Drive Chain...349
Secondary Drive Chain Removal...349
To Install The Secondary Drive Chain...349
Final Drive Chain Removal...349
To Install The Final Drive Chain...350
MOTOR SPROCKET SERVICE...350
Motor Sprocket Removal (Machines Without Brakes)...350
To Install The Motor Sprocket (Machines Without Brakes)...350
Motor Sprocket Removal (Machines With Brakes)...350
To Install The Motor Sprocket (Machines With Brakes)...351
UPPER JACKSHAFT SERVICE...351
To Remove The Upper Jackshaft Sprocket...351
Assembly...352
To Install Tjhe Upper Jackshaft Sprocket...352
IDLER SPROCKET SERVICE (PRIMARY AND SECONDARY)...352
SERVICING LOWER JACKSHAFT SPROCKET...352
To Remove The Lower Jackshaft Assembly...352
To Install The Lower Jackshaft Assembly...353
Lower Jackshaft Bearing Replacement...353
FINAL DRIVE TIGHTENER SERVICE...353
To Remove Final Drive Tightener...353
To Remove Final Drive Idler Sprocket And Bearing...354
To Install Final Drive Idler Bearing...354
WHEEL AND AXLE REPAIR...354
To Remove Axle Assembly...354
To Install New Axle Bearing And Seal...355
To Install The Axle...356
MAIN FRAME...357
THE BOB-TACH...359
Removal And Replacement Of Bob-Tach...359
LOADER LIFT ARM ASSEMBLY...359
Replacement Of Lift Arms...359
GRILL ASSEMBLY...360
FUEL TANK...360
Fuel Tank Removal...360
ELECTRICAL SYSTEM...361
ELECTRICAL CIRCUITRY...363
PROBLEM ANALYSIS CHARTS...363
GENERATOR DRIVE BELT...365
TO CHECK WIRING...365
TO CHECK GENERATOR OUTPUT...365
TO CHECK THE REGULATOR...366
GENERATOR SERVICE...366
Removal ...366
Disassembly...366
To Check Rotor...366
To Check Stator...366
To Check Diode Trio...367
To Check Rectifier...367
Assembly...367
STARTER SERVICE...368
To Check The Starter...368
To Remove The Starter...368
Disassembly And Inspection...368
Assembly...368
WISCONSIN ENGINE SERVICE...369
TROUBLESHOOTING THE ENGINE...371
ENGINE IGNITION SYSTEM...372
Distributor Maintenance...372
Timing Procedure...372
Spark Plug...372
High Temperature Safety Switches...373
CARBURETOR SERVICE...373
Adjustment...373
Carburetor Removal & Disassembly...373
To remove The Throttle Body Assembly...373
To Disassemble The Throttle Body...373
To Disassemble The Fuel Bowl...374
To Assemble The Fuel Bowl And Air Intake Assembly...374
To Assemble The Throttle Body...375
To Assemble The Fuel Bowl To The Throttle Body...375
LP CARBURETOR SERVICE...376
To remove The LP Carburetor From The Engine...376
Disassembly...376
Cleaning And Inspection...376
Assembly...377
VAPORIZER - PRIMARY REGULATOR SERVICE...378
Disassembling The Vaporizer...379
Assembling The Vaporizer...379
Adjusting The Vaporizer...380
LP FUEL FILTER LOCK-OFF...380
ENGINE SERVICE...381
Engine Removal...381
Disassembly Of Flywheel...382
Air Shrouding...382
Carburetor And Manifolds...382
Cylinder Head...382
Gear Cover...383
Camshaft Gear...383
Idler Gear And Shaft...383
Oil Pan...383
Oil Pump...383
Pistons And Connecting Rods...383
Piston Rings...384
Cylinder Blocks...384
Valves And Seat Inserts...385
Crankshaft...385
Camshaft...385
Valve Tappets...385
Govenor Adjustment...386
Storage Of Engines...386
Returning Engine To Service...386
Returning Compression To Engine...386
SPECIFICATIONS, SPECIAL TOOLS AND ETC...387
FUEL SPECIFICATIONS...389
ENGINE OIL SPECIFICATIONS...389
HYDRAULIC / HYDROSTATIC TRANSMISSION FLUID...389
FITS, CLEARANCE AND ADJUSTMENTS...390
Engine...390
Hydraulic / Hydrostatic System...390
SPECIAL TOOLS...390
Main Frame & Hydraulics...390
Wisconsin Engine...391
Hydrostatic System...391
LP Carburetor...391
TORQUE SPECIFICATIONS...391
Loader Torques...391
EngineTorques...391
DECIMAL AND MILLIMETER EQUIVALENTS...392
U.S. TO METRIC CONVERSION...392
LOADER SPECIFICATIONS...393
Operational & Performance...393
Engine...393
Loader Hydraulics...393
Electrical...393
Power Train...393
Capacities...393
Tires...393
Machine Weight...393
ALPHABETICAL INDEX...395
6556099 (11-86) - 610 Operation & Maintenance Manual...399
WARNINGS...401
FOREWORD...403
CONTENTS...403
610 LOADER...404
OPERATING INSTRUCTIONS...405
OPERATING INSTRUCTIONS...407
CONTROLS...408
DASH PANEL...408
HOUR METER...409
THROTTLE CONTROL...409
CHOKE CONTROL...409
VARIABLE SPEED CONTROL...409
STEERING CONTROLS...409
PARKING BRAKE...410
HYDRAULIC CONTROLS...410
FOLLOW RECOMMENDED STARTING PROCEDURES...411
STARTING PROCEDURE...412
Pre-Starting Inspection...412
Starting ...412
Normal Starting Condition...412
Cold Temperature Starting Condition...413
OPERATION OF THE BOBCAT LOADER...413
Bucket Size...413
Installing Attachment...413
To Remove Attachment...414
OPERATION OF THE BOBCAT...414
Operating Procedure...414
Filling Bucket From A Quantity Of Material...415
To Empty The Bucket...415
Removing Dirt...415
Leveling...416
Backfilling...416
STOPPING THE BOBCAT LOADER...416
TRANSPORTING THE BOBCAT...416
PREVENTIVE MAINTENANCE...417
SERVICE SCHEDULE...419
AIR CLEANER SERVICE...420
FUEL SYSTEM...420
FUEL SYSTEM SERVICE...421
FUEL FILTER...421
ENGINE LUBRICATION SYSTEM...421
REPLACEMENT OF ENGINE OIL AND FILTER...422
ENGINE COOLING SYSTEM...422
ELECTRICAL SYSTEM...423
USING AN EXTRA BATTERY...423
TO INSTALL A NEW BATTERY...425
OPERATOR GUARD (ROPS)...425
CHANGING AND ADDING HYDRAULIC FLUID...426
DRAINING CONDENSATION...426
DIRECTIONAL CONTROL CLUTCHES...426
VARIABLE SPEED DRIVE...427
DRIVE BELT REPLACEMENT...428
DRIVE CHAIN ADJUSTMENT...428
REPLACEMENT OF HYDRAULIC FILTER...430
HYDRAULIC OIL LEAKS...431
QUICK COUPLERS...431
CONTROL PEDAL LINKAGE ADJUSTMENT...431
TIRE MAINTENANCE...431
Tire Rotation...431
LUBRICATION OF THE BOBCAT LOADER...432
BOB-TACH...432
PIVOT PINS...432
DELIVERY REPORT...433
THIRTY HOUR INSPECTION...433
TROUBLESHOOTING...435
TROUBLESHOOTING THE ENGINE...437
TROUBLESHOOTING THE DRIVE SYSTEM...438
TROUBLESHOOTING THE HYDRAULIC SYSTEM...439
MAJOR PARTS...441
MAIN FRAME...443
DRIVE SYSTEM...444
HYDRAULIC SYSTEM...445
LOADER HYDRAULICS...446
ELECTRICAL CIRCUITRY...447
ENGINE & aTTACHING PARTS...448
ENGINE SHROUDING...449
DECALS...450
GENERAL INFORMATION...451
LOADER SPECIFICATIONS...453
OPERATION & PERFORMANCE...453
ENGINE...453
LOADER HYDRAULICS...453
ELECTRICAL...454
POWER TRAIN...454
CAPACITIES...454
TIRES...454
MACHINE TORQUES...454
PALLET FORK WEIGHT DISTRIBUTION...454
6556100 (3-77) - 611 Operation & Maintenance Manual...455
OPERATOR SAFETY WARNINGS...456
FOREWORD...457
BOBCAT LOADER PICTORIAL NOMENCLATURE...458
OPERATING INSTRUCTIONS...459
OPERATING INSTRUCTIONS...460
CONTROLS...461
DASH PANEL...461
HOURMETER...462
THROTTLE CONTROL...462
CARIABLE SPEED CONTROL...462
STEERING CONTROLS...462
PARKING BRAKE...463
HYDRAULIC CONTROLS...463
Auxiliary Control...464
STARTING PROCEDURE...464
Pre-Starting Inspection...464
Starting...464
Normal Starting Condition...464
Cold Temperature Starting Condition...465
BOBCAT OPERATION...465
Bucket Size...465
Installing Attachment...465
To Remove Attachment...466
OPERATING THE BOBCAT LOADER...466
Operating Hints...466
Filling Bucket From A Pile...466
Dumping The Bucket...467
Breaking Ground (Digging)...467
Leveling...467
Backfilling...468
TRANSPORTING THE BOBCAT ...468
PREVENTIVE MAINTENANCE...470
SERVICE & MAINTENANCE...471
SERVICE SCHEDULE...472
AIR CLEANER SYSTEM...473
FUEL SYSTEM...473
ENGINE FUEL...473
FUEL SYSTEM SERVICE...474
FUEL FILTER...474
AIR VENTING THE FUEL SYSTEM...475
ENGINE LUBRICATION SYSTEM...475
OIL SPECIFICATIONS...475
CHANGING ENGINE OIL...476
ENGINE OIL FILTER...476
CRANKCASE BREATHER...477
ENGINE COOLING SYSTEM...477
ELECTRICAL SYSTEM...478
USING A BOOSTER BATTERY...478
CHANGING AND ADDING HYDRAULIC FLUID...479
To Check Fluid Level...479
DRAINING CONDENSATION...479
DIRECTIONAL CONTROL CLUTCHES...479
VARIABLE SPEED DRIVE...480
DRIVE BELT REPLACEMENT...481
DRIVE CHAIN ADJUSTMENT...481
HYDRAULIC FLUID FILTER REPLACEMENT...483
HYDRAULIC FLUID LEAKS...484
QUICK COUPLERS...484
CONTROL PEDAL LINKAGE ADJUSTMENT...484
TIRE MAINTENANCE...484
Tire Rotation...484
LUBRICATION OF LOADER...485
BOB-TACH...485
PIVOT PINS...485
PRE-DELIVERY INSPECTION...486
DELIVERY REPORT...486
THIRTY HOUR INSPECTION...486
TROUBLESHOOTING...488
TROUBLESHOOTING THE ENGINE...490
TROUBLESHOOTING THE HYDRAULIC SYSTEM...491
TROUBLESHOOTING THE DRIVE SYSTEM...492
MAJOR PARTS...496
MAIN FRAME PARTS...498
ENGINE & ATTACHING PARTS...499
DRIVE SYSTEM...500
HYDRAULIC CIRCUITRY...501
LOADER HYDRAULICS...502
ELECTRICAL CIRCUITRY...503
SPECIFICATIONS...504
OPERATIONAL & PERFORMANCE...504
ENGINE...504
LOADER HYDRAULICS...504
ELECTRICAL...504
POWER TRAIN...504
CAPACITIES...504
TIRES...504
COUNTERWEIGHT...504
WARRANTY...506
6556276 (6-12) - 600, 600D, 610, 611 Service Manual...508
MAINTENANCE SAFETY...510
CONTENTS...512
FOREWORD...512
GENERAL SERVICE...514
SERVICE SCHEDULE...516
TIRES...517
LOADER LUBRICATION...517
CHANGING AND ADDING HYDRAULIC OIL...517
REMOVING WATER FROM HYDRAULIC TANKS...517
BOB–TACH FRAME...518
HYDRAULIC FLUID FILTERCHANGE...518
ENGINE AIR CLEANER...519
OIL TYPE AIR CLEANER...519
HEAVY DUTY AIR CLEANER...519
ENGINE OIL...520
OIL SPECIFICATIONS FOR ENGINES...520
ENGINE OIL FILTER (Wisconsin)...521
ENGINE OIL FILTER (Duetz Diesel)...521
OIL FILTER (Petter)...521
CRANKCASE AIR VENT (Wisconsin)...522
CRANKCASE AIR VENT (Deutz)...522
FUEL SPECIFICATIONS...522
FUEL FILTER...522
EXCESS FUEL LEVER ADJUSTMENT (Deutz Engine)...524
FUEL PUMP (Wisconsin)...524
FUEL ADJUSTMENT (Petter)...525
ENGINE COOLING SYSTEM...525
WATER SCRUBBER MUFFLER (600 Diesel)...525
IGNITION TIMING (Wisconsin Engine)...526
DISTRIBUTOR MAINTENANCE (Wisconsin)...527
SPARK PLUG (Wisconsin)...527
ELECTRICAL SYSTEMS...528
CHECKING REGULATOR AND RECTIFIER...528
STATOR CHECKS...529
ALTERNATOR CHECK...531
REGULATOR CHECK #1...531
REGULATOR CHECK #2...531
REGULATOR CHECK #3...532
TROUBLESHOOTING...538
TROUBLESHOOTING THE DRIVE SYSTEM...540
TROUBLESHOOTING THE HYDRAULIC SYSTEM...544
TROUBLESHOOTING THE ENGINE...550
DRIVE SYSTEM...556
CLUTCH ADJUSTMENT...559
Adjustment Procedure...559
Steering Clutch Adjustment...560
DISASSEMBLY & ASSEMBLY...562
Disassembly...562
Assembly...564
INSTALLING CLUTCH NEEDLE BEARINGS...568
DRIVE BELT INSTALLATION (Split Shaft)...568
REMOVAL OF DRIVEN SHEAVE...570
INSTALLING OF DRIVEN SHEAVE...571
DRIVEN SHEAVE DISASSEMBLY...572
ASSEMBLY OF DRIVEN SHEAVE (TAPERED JACKSHAFT)...572
DISASSEMBLY OF DRIVE SHEAVE (STRAIGHT JACKSHAFT)...573
ASSEMBLY OF DRIVEN SHEAVE (STRAIGHT JACKSHAFT)...573
DRIVEN SHEAVE ALIGNMENT...573
JACKSHAFT BEARING INSTALLATION...574
REMOVAL OF VARIABLE DRIVE SHEAVE WITH ROTO SWIVEL INSIDE (600, 610 Gasoline and Diesel, Serial Number 72319 and Up)...575
ROTO–SWIVEL DISASSEMBLY...576
ROTO–SWIVEL ASSEMBLY...576
ASSEMBLY PROCEDURES FOR 610 VARIABLE SPEED WITH ROTO–SWIVEL INSIDE...576
REMOVAL OF VARIABLE SHEAVE WITH ROTO–SWIVEL OUTSIDE (600 Gasoline, LP and Diesel; Serial Number 67253–72318)...577
REMOVAL OF FRAME SUPPORT VARIABLE SHEAVE (600 Gasoline and LP; serial Number 62796–67252)...577
AXLE REMOVAL (FRONT AXLE)...578
AXLE BEARING AND SEAL INSTALLATION...579
INSTALLATION OF AXLE...580
AXLE SPROCKET REMOVAL & INSTALLATION...581
LOWER JACKSHAFT REMOVAL...582
LOWER JACKSHAFT SPROCKET REPAIR...583
LOWER JACKSHAFT INSTALLATION...583
DRIVE CHAIN ADJUSTMENT...585
BRAKE ASSEMBLY...587
ASSEMBLY OF BRAKE...587
BRAKE ADJUSTMENT...588
HYDRAULIC SYSTEM...590
HYDRAULIC SYSTEM...592
Hydraulic Circuit Operation...592
HYDRAULIC SYSTEM (600 Electric and 600 Diesel W/Petter Engine) (Hydraulic Flow)...593
Hydraulic System (600, 610 Gasoline and LP Gas) (Hydraulic Fluid Flow)...592
HYDRAULIC SYSTEM (600 and 610 Diesel W/Deutz Engine) (Hydraulic Flow)...592
RESTRICTOR FOR TILT HYDRAULIC CIRCUIT (Grapple Operation Only)...593
CHECKING THE CONDITION OF HYDRAULIC SYSTEM...593
RECOMMENDED HYDRAULIC OILFLOW RATE...594
CHECKING CONDITION OF HYDRAULIC PUMP...594
CHECKING THE PRESSURE SETTING OF THE CARTRIDGE RELEASE (In Lift and Auxiliary Control Valve)...595
MASTER RELEASE VALVE ADJUSTMENT...595
CARTRIDGE RELEASE ADJUSTMENT...595
CHECKING VARIABLE SPEED VALVE PRESSURE ADJUSTMENT (Variable Speed Swivel Couplings)...596
Variable Speed Control Valve With Holding Pressure Release Valve...596
CHECKING PRESSURE ADJUSTMENT (Variable Speed Control Valve with no Holding Pressure Valve )...597
VARIABLE SPEED CLOSING PRESSURE ADJUSTMENT (Variable Speed Control Valve with or with no Holding Release Valve)...597
VARIABLE SPEED HOLDING RELEASE PRESSURE SETTING (600 PSI [4137 kPa] Minimum)...597
DISASSEMBLY OF VARIABLE SPEED CONTROL VALVE (Seal Replacement with Control Valve in the Bobcat)...598
ASSEMBLY OF VARIABLE SPEED CONTROL VALVE, SEAL REPLACEMENT WITH CONTROL VALVE IN THE BOBCAT (With Holding Release Valve)...598
CONTROL VALVE SEAL INSTALLATION...599
INSTALLING VALVE SPOOL SEALS IN THE VARIABLE SPEED CONTROL VALVE...600
HYDRAULIC PUMP SERVICE (Webster Pump)...601
DISASSEMBLY...601
ASSEMBLY OF HYDRAULIC PUMP (Webster Pump)...602
HYDRAULIC PUMP DISASSEMBLY (Cessna Pump)...603
HYDRAULIC PUMP ASSEMBLY (Cessna Pump)...603
HYDRAULIC LIFT OR TILT CYLINDER DISASSEMBLY...604
INSTALLATION OF CYLINDER SEALS...604
HYDRAULIC CYLINDER ASSEMBLY ...604
HYDRAULIC PUMP ALIGNMENT (500 ELECTRIC)...605
HYDRAULIC PUMP ALIGNMENT (600 Wisconsin)...606
37° Flare Connections...607
Tubelines and Hoses...607
Installing O–Rings...607
WISCONSIN ENGINE SERVICE...608
RETURN OF NORMAL COMPRESSION...610
GOVERNOR ADJUSTMENT...610
STORAGE OF ENGINE...611
RETURN STORED ENGINE TO SERVICE...611
CARBURETOR ADJUSTMENT...611
CARBURETOR RECONDITIONING ...611
TO DISASSEMBLE THROTTLE BODY...611
DISASSEMBLY OF THE FUEL BOWL...612
O ASSEMBLE FUEL BOWL AND INTAKE ASSEMBLY...612
TO ASSEMBLE THROTTLE BODY...613
ASSEMBLY OF FUEL BOWL AND THROTTLE BODY...613
LP CARBURETOR SERVICE...614
CARBURETOR REMOVAL...614
LP CARBURETOR RECONDITIONING...614
DISASSEMBLY PROCEDURE LP CARBURETOR...614
CLEANING AND INSPECTION...615
ASSEMBLE LP CARBURETOR...615
VAPORIZER & PRIMARY REGULATOR SERVICE...617
DISASSEMBLING THE VAPORIZER...617
TO ASSEMBLE THE VAPORIZER...617
ADJUSTMENT OF VAPORIZER...618
LP FUEL FILTER LOCK–OFF...619
FUEL FILTER LOCK–OFF DISASSEMBLY...619
ENGINE RECONDITIONING...620
REMOVAL OF ENGINE...620
REMOVAL OF ACCESSORIES...620
REMOVAL OF FLYWHEEL...620
REMOVAL OF AIR HOUSING...620
REMOVAL OF CARBURETOR AND MANIFOLD...621
REMOVAL OF CYLINDER HEAD...621
REMOVAL OF GEAR COVER...621
REMOVAL OF CAMSHAFT...621
REMOVAL OF IDLER GEARAND SHAFT...621
REMOVAL OF OIL PAN...621
REMOVAL OF OIL PUMP...621
REMOVAL OF PISTONS AND CONNECTING RODS...622
REMOVAL OF VALVES AND SEAT INSERTS...622
REMOVAL OF CYLINDER BLOCK...623
REMOVAL OF CRANKSHAFT...623
REMOVAL OF CAMSHAFT...623
REMOVAL OF VALVE TAPPET...623
ASSEMBLY OF ENGINE AFTER RECONDITIONING INSTALLATION OF VALVE TAPPETS...623
INSTALLATION OF CAMSHAFT...623
INSTALLATION OF CRANKSHAFT...624
INSTALLATION OF VALVES AND SEAT INSERTS...624
INSTALLATION OF CYLINDER BLOCKS...624
INSTALLATION OF PISTON RINGS...624
INSTALLATION OF PISTONS AND CONNECTING RODS...625
INSTALLATION OF OIL PUMP...625
OIL PAN INSTALLATION...625
INSTALLATION OF IDLER GEAR AND SHAFT...626
INSTALLATION OF CAMSHAFT GEAR...626
INSTALLATION OF GEAR COVER...626
INSTALLATION OF CYLINDER HEAD...626
INSTALLATION OF CARBURETOR AND MANIFOLD ASSEMBLY...627
INSTALLATION OF AIR HOUSING...627
INSTALLATION OF FLYWHEEL...627
INSTALLATION OF ACCESSORIES...627
DEUTZ ENGINE SERVICE...628
INSTRUCTIONS FOR TIGHTENING BOLTS AND STUDS...630
CHECK AND ADJUSTMENTS...630
Adjustment of Valve Clearance...630
Compression Check...631
Checking Fuel System...631
Checking Fuel Injection Pump...631
To Find top Dead Center And Start Of Fuel Injection...632
Adjustment Of Start Of Fuel Injection...632
ENGINE RECONDITIONING...633
TO ASSEMBLE THE ENGINE...635
INSPECTION AND REPAIR...646
Checking The Crankshaft...646
Reconditioning Crankshaft...646
Checking Crankcase...646
Checking And Installing Main Bearing...647
Checking And Installing Camshaft And Bearings...648
Checking The Oil Pump...649
Installing A New Gear Starter Ring On Flywheel...649
Checking Front Cover And Repair Of Engine Governor...649
Check and Repair Of The Governor...652
Checking And Replacement Of Connecting Rod Bearings...653
Checking And Replacement Of Piston Pin Bushing...654
Checking Cylinders...654
Checking And Measuring Pistons...654
Repair Of Cylinder Head...655
Repair Of Rocker Arms...658
Repair Of Cooling Air Blower...658
Removing And Installing A Fuel Injection Nozzle...659
GENERAL ENGINE DATA (F2L410)...660
Torque Specifications (Deutz Engine)...660
FITS, CLEARANCES, ADJUSTMENTS – DEUTZ ENGINE...661
Oil System...661
Fuel System...661
Governor, Front Cover and Throttle...661
Cylinder Head and Valves...661
Cylinder and Piston...661
Camshaft, Crankshaft, Bearings...662
SPECIAL TOOLS...662
Mainframe & Hydraulics...662
Deutz Engine Tools...662
PETTER ENGINE SERVICE...664
ENGINE DISASSEMBLY AND REPAIR...666
Removal Of Connecting Rod...667
Removal Of Crankshaft...667
Removal Of Camshaft...668
Removal Of Oil Pump And Governor Assembly...669
Oil Filter...669
Lubricating Oil Pump...671
Installation Of Camshaft...672
Connecting Rod Assembly...673
Installation Of Cylinders And Pistons...673
Piston Assembly...674
Installation Of Cylinder Heads...674
Installation Of Valve Rocker Gear...675
Adjustment Of Valve Rockers...675
Adjustment Of Decompressor...675
Fuel Pump Installation...675
Fuel Filter Assembly...675
Fuel And Oil Filter Assembly...675
Timing The Engine...675
Injector Installation...676
TECHNICAL DATA (Fits, Clearances & Torques)...677
SPECIFICATIONS...678
ENGINE SPECIFICATIONS (WISCONSIN)...680
ENGINE SPECIFICATIONS (Wisconsin)...682
Fuel Specifications...682
Engine Oil...682
Specifications...682
Valve Mechanism...683
Crankshaft...683
Idler Gear...683
Connecting Rod...683
Piston, Piston Pin, Piston Rings...683
Ignition System...683
Distributor Advance Characteristics...683
Starter...683
Engine Torque Specifications...683
600 LOADER (WISCONSIN GAS)...684
OPERATIONAL & PERFORMANCE...684
ENGINE...684
LOADER HYDRAULICS...684
ELECTRICAL...684
DRIVE SYSTEM...684
CAPACITIES...684
COUNTERWEIGHT...684
MACHINE WEIGHT (Less Bucket)...684
610 LOADER (WISCONSIN GAS)...685
OPERATIONAL & PERFORMANCE...685
ENGINE...685
LOADER HYDRAULICS...685
ELECTRICAL...685
DRIVE SYSTEM...685
CAPACITIES...685
COUNTERWEIGHT...685
MACHINE WEIGHT (Less Attachments)...685
ENGINE SPECIFICATIONS (DEUTZ)...686
ENGINE SPECIFICATIONS (Deutz F2L 411)...688
Fuel System...688
Lubrication System...688
overn, Front Cover and Throttle...689
Cylinder Head and Valves...689
Cylinder, Piston and Connecting Rod...689
Camshaft, Crankshaft, Bearings...689
Torque Specifications...690
Special Tools...690
600D LOADER (DEUTZ DIESEL)...691
OPERATIONAL & PERFORMANCE...691
ENGINE...691
LOADER HYDRAULICS...691
ELECTRICAL...691
DRIVE SYSTEM...691
CAPACITIES...691
TIRES...691
COUNTERWEIGHT...691
MACHINE WEIGHT (Less Bucket)...691
611 LOADER (DEUTZ DIESEL)...692
OPERATIONAL & PERFORMANCE...692
ENGINE...692
LOADER HYDRAULICS...692
ELECTRICAL...692
DRIVE SYSTEM...692
CAPACITIES...692
TIRES...692
COUNTERWEIGHT...692
MACHINE WEIGHT (Less Bucket)...692
611D LOADER (BUREAU OF MINES APPROVED)...693
OPERATIONAL & PERFORMANCE...693
ENGINE...693
LOADER HYDRAULICS...693
ELECTRICAL...693
DRIVE SYSTEM...693
CAPACITIES...693
TIRES...693
COUNTERWEIGHT...693
MACHINE WEIGHT (Less Attachments)...693
ENGINE SPECIFICATIONS (PETTER)...694
ENGINE SPECIFICATIONS (Petter)...696
Fuel Specifications...696
Engine Oil...696
Specifications...696
Lubrication System...696
Cylinder Head...697
Valve Mechanism...697
Camshaft...697
Crankshaft...697
Crankshaft Regrinding Diameters...697
Connecting Rod...697
Piston...697
Cylinder Block...697
Torque Specifications...698
600D LOADER (DEUTZ DIESEL)...699
OPERATIONAL & PERFORMANCE...699
ENGINE...699
LOADER HYDRAULICS...699
ELECTRICAL...699
DRIVE SYSTEM...699
CAPACITIES...699
TIRES...699
COUNTERWEIGHT...699
MACHINE WEIGHT (Less Bucket)...699
MOTOR SPECIFICATIONS, (ELECTRIC)...700
600E LOADER (RELIANCE ELECTRIC)...702
OPERATIONAL & PERFORMANCE...702
MOTOR...702
LOADER HYDRAULICS...702
POWER TRAIN...702
CAPACITIES...702
TIRES...702
COUNTERWEIGHT...702
MACHINE WEIGHT (Less Attachment)...702
TECHNICAL DATA...704
LOADER TORQUE SPECIFICATIONS...706
Hydraulic Fluid...706
Special Tools...706
DECIMAL AND MILLIMETER EQUIVALENTS...707
U.S. TO METRIC CONVERSION...707
STANDARD TORQUE SPECIFICATIONS FOR BOLTS...708
ALPHABETICAL INDEX...712
SERVICE BULLETINS...712
019...714
042...716
SERVICE MANUAL REVISIONS...714
600-002...718
600-003...720
600-004...722
6556276 (6-87) - 600, 600D, 610, 611 Service Manual...724
MAINTENANCE SAFETY...726
CONTENTS...728
FOREWORD...728
GENERAL SERVICE...730
SERVICE SCHEDULE...732
TIRES...733
LOADER LUBRICATION...733
CHANGING AND ADDING HYDRAULIC OIL...733
REMOVING WATER FROM HYDRAULIC TANKS...733
BOB–TACH FRAME...734
HYDRAULIC FLUID FILTERCHANGE...734
ENGINE AIR CLEANER...735
OIL TYPE AIR CLEANER...735
HEAVY DUTY AIR CLEANER...735
ENGINE OIL...736
OIL SPECIFICATIONS FOR ENGINES...736
ENGINE OIL FILTER (Wisconsin)...737
ENGINE OIL FILTER (Duetz Diesel)...737
OIL FILTER (Petter)...737
CRANKCASE AIR VENT (Wisconsin)...738
CRANKCASE AIR VENT (Deutz)...738
FUEL SPECIFICATIONS...738
FUEL FILTER...738
EXCESS FUEL LEVER ADJUSTMENT (Deutz Engine)...740
FUEL PUMP (Wisconsin)...740
FUEL ADJUSTMENT (Petter)...741
ENGINE COOLING SYSTEM...741
WATER SCRUBBER MUFFLER (600 Diesel)...741
IGNITION TIMING (Wisconsin Engine)...742
DISTRIBUTOR MAINTENANCE (Wisconsin)...743
SPARK PLUG (Wisconsin)...743
ELECTRICAL SYSTEMS...744
CHECKING REGULATOR AND RECTIFIER...744
STATOR CHECKS...745
ALTERNATOR CHECK...747
REGULATOR CHECK #1...747
REGULATOR CHECK #2...747
REGULATOR CHECK #3...748
TROUBLESHOOTING...754
TROUBLESHOOTING THE DRIVE SYSTEM...756
TROUBLESHOOTING THE HYDRAULIC SYSTEM...760
TROUBLESHOOTING THE ENGINE...766
DRIVE SYSTEM...772
CLUTCH ADJUSTMENT...775
Adjustment Procedure...775
Steering Clutch Adjustment...776
DISASSEMBLY & ASSEMBLY...778
Disassembly...778
Assembly...780
INSTALLING CLUTCH NEEDLE BEARINGS...784
DRIVE BELT INSTALLATION (Split Shaft)...784
REMOVAL OF DRIVEN SHEAVE...786
INSTALLING OF DRIVEN SHEAVE...787
DRIVEN SHEAVE DISASSEMBLY...788
ASSEMBLY OF DRIVEN SHEAVE (TAPERED JACKSHAFT)...788
DISASSEMBLY OF DRIVE SHEAVE (STRAIGHT JACKSHAFT)...789
ASSEMBLY OF DRIVEN SHEAVE (STRAIGHT JACKSHAFT)...789
DRIVEN SHEAVE ALIGNMENT...789
JACKSHAFT BEARING INSTALLATION...790
REMOVAL OF VARIABLE DRIVE SHEAVE WITH ROTO SWIVEL INSIDE (600, 610 Gasoline and Diesel, Serial Number 72319 and Up)...791
ROTO–SWIVEL DISASSEMBLY...792
ROTO–SWIVEL ASSEMBLY...792
ASSEMBLY PROCEDURES FOR 610 VARIABLE SPEED WITH ROTO–SWIVEL INSIDE...792
REMOVAL OF VARIABLE SHEAVE WITH ROTO–SWIVEL OUTSIDE (600 Gasoline, LP and Diesel; Serial Number 67253–72318)...793
REMOVAL OF FRAME SUPPORT VARIABLE SHEAVE (600 Gasoline and LP; serial Number 62796–67252)...793
AXLE REMOVAL (FRONT AXLE)...794
AXLE BEARING AND SEAL INSTALLATION...795
INSTALLATION OF AXLE...796
AXLE SPROCKET REMOVAL & INSTALLATION...797
LOWER JACKSHAFT REMOVAL...798
LOWER JACKSHAFT SPROCKET REPAIR...799
LOWER JACKSHAFT INSTALLATION...799
DRIVE CHAIN ADJUSTMENT...801
BRAKE ASSEMBLY...803
ASSEMBLY OF BRAKE...803
BRAKE ADJUSTMENT...804
HYDRAULIC SYSTEM...806
HYDRAULIC SYSTEM...808
Hydraulic Circuit Operation...808
HYDRAULIC SYSTEM (600 Electric and 600 Diesel W/Petter Engine) (Hydraulic Flow)...809
Hydraulic System (600, 610 Gasoline and LP Gas) (Hydraulic Fluid Flow)...808
HYDRAULIC SYSTEM (600 and 610 Diesel W/Deutz Engine) (Hydraulic Flow)...808
RESTRICTOR FOR TILT HYDRAULIC CIRCUIT (Grapple Operation Only)...809
CHECKING THE CONDITION OF HYDRAULIC SYSTEM...809
RECOMMENDED HYDRAULIC OILFLOW RATE...810
CHECKING CONDITION OF HYDRAULIC PUMP...810
CHECKING THE PRESSURE SETTING OF THE CARTRIDGE RELEASE (In Lift and Auxiliary Control Valve)...811
MASTER RELEASE VALVE ADJUSTMENT...811
CARTRIDGE RELEASE ADJUSTMENT...811
CHECKING VARIABLE SPEED VALVE PRESSURE ADJUSTMENT (Variable Speed Swivel Couplings)...812
Variable Speed Control Valve With Holding Pressure Release Valve...812
CHECKING PRESSURE ADJUSTMENT (Variable Speed Control Valve with no Holding Pressure Valve )...813
VARIABLE SPEED CLOSING PRESSURE ADJUSTMENT (Variable Speed Control Valve with or with no Holding Release Valve)...813
VARIABLE SPEED HOLDING RELEASE PRESSURE SETTING (600 PSI [4137 kPa] Minimum)...813
DISASSEMBLY OF VARIABLE SPEED CONTROL VALVE (Seal Replacement with Control Valve in the Bobcat)...814
ASSEMBLY OF VARIABLE SPEED CONTROL VALVE, SEAL REPLACEMENT WITH CONTROL VALVE IN THE BOBCAT (With Holding Release Valve)...814
CONTROL VALVE SEAL INSTALLATION...815
INSTALLING VALVE SPOOL SEALS IN THE VARIABLE SPEED CONTROL VALVE...816
HYDRAULIC PUMP SERVICE (Webster Pump)...817
DISASSEMBLY...817
ASSEMBLY OF HYDRAULIC PUMP (Webster Pump)...818
HYDRAULIC PUMP DISASSEMBLY (Cessna Pump)...819
HYDRAULIC PUMP ASSEMBLY (Cessna Pump)...819
HYDRAULIC LIFT OR TILT CYLINDER DISASSEMBLY...820
INSTALLATION OF CYLINDER SEALS...820
HYDRAULIC CYLINDER ASSEMBLY ...820
HYDRAULIC PUMP ALIGNMENT (500 ELECTRIC)...821
HYDRAULIC PUMP ALIGNMENT (600 Wisconsin)...822
37° Flare Connections...823
Tubelines and Hoses...823
Installing O–Rings...823
WISCONSIN ENGINE SERVICE...824
RETURN OF NORMAL COMPRESSION...826
GOVERNOR ADJUSTMENT...826
STORAGE OF ENGINE...827
RETURN STORED ENGINE TO SERVICE...827
CARBURETOR ADJUSTMENT...827
CARBURETOR RECONDITIONING ...827
TO DISASSEMBLE THROTTLE BODY...827
DISASSEMBLY OF THE FUEL BOWL...828
O ASSEMBLE FUEL BOWL AND INTAKE ASSEMBLY...828
TO ASSEMBLE THROTTLE BODY...829
ASSEMBLY OF FUEL BOWL AND THROTTLE BODY...829
LP CARBURETOR SERVICE...830
CARBURETOR REMOVAL...830
LP CARBURETOR RECONDITIONING...830
DISASSEMBLY PROCEDURE LP CARBURETOR...830
CLEANING AND INSPECTION...831
ASSEMBLE LP CARBURETOR...831
VAPORIZER & PRIMARY REGULATOR SERVICE...833
DISASSEMBLING THE VAPORIZER...833
TO ASSEMBLE THE VAPORIZER...833
ADJUSTMENT OF VAPORIZER...834
LP FUEL FILTER LOCK–OFF...835
FUEL FILTER LOCK–OFF DISASSEMBLY...835
ENGINE RECONDITIONING...836
REMOVAL OF ENGINE...836
REMOVAL OF ACCESSORIES...836
REMOVAL OF FLYWHEEL...836
REMOVAL OF AIR HOUSING...836
REMOVAL OF CARBURETOR AND MANIFOLD...837
REMOVAL OF CYLINDER HEAD...837
REMOVAL OF GEAR COVER...837
REMOVAL OF CAMSHAFT...837
REMOVAL OF IDLER GEARAND SHAFT...837
REMOVAL OF OIL PAN...837
REMOVAL OF OIL PUMP...837
REMOVAL OF PISTONS AND CONNECTING RODS...838
REMOVAL OF VALVES AND SEAT INSERTS...838
REMOVAL OF CYLINDER BLOCK...839
REMOVAL OF CRANKSHAFT...839
REMOVAL OF CAMSHAFT...839
REMOVAL OF VALVE TAPPET...839
ASSEMBLY OF ENGINE AFTER RECONDITIONING INSTALLATION OF VALVE TAPPETS...839
INSTALLATION OF CAMSHAFT...839
INSTALLATION OF CRANKSHAFT...840
INSTALLATION OF VALVES AND SEAT INSERTS...840
INSTALLATION OF CYLINDER BLOCKS...840
INSTALLATION OF PISTON RINGS...840
INSTALLATION OF PISTONS AND CONNECTING RODS...841
INSTALLATION OF OIL PUMP...841
OIL PAN INSTALLATION...841
INSTALLATION OF IDLER GEAR AND SHAFT...842
INSTALLATION OF CAMSHAFT GEAR...842
INSTALLATION OF GEAR COVER...842
INSTALLATION OF CYLINDER HEAD...842
INSTALLATION OF CARBURETOR AND MANIFOLD ASSEMBLY...843
INSTALLATION OF AIR HOUSING...843
INSTALLATION OF FLYWHEEL...843
INSTALLATION OF ACCESSORIES...843
DEUTZ ENGINE SERVICE...844
INSTRUCTIONS FOR TIGHTENING BOLTS AND STUDS...846
CHECK AND ADJUSTMENTS...846
Adjustment of Valve Clearance...846
Compression Check...847
Checking Fuel System...847
Checking Fuel Injection Pump...847
To Find top Dead Center And Start Of Fuel Injection...848
Adjustment Of Start Of Fuel Injection...848
ENGINE RECONDITIONING...849
TO ASSEMBLE THE ENGINE...851
INSPECTION AND REPAIR...862
Checking The Crankshaft...862
Reconditioning Crankshaft...862
Checking Crankcase...862
Checking And Installing Main Bearing...863
Checking And Installing Camshaft And Bearings...864
Checking The Oil Pump...865
Installing A New Gear Starter Ring On Flywheel...865
Checking Front Cover And Repair Of Engine Governor...865
Check and Repair Of The Governor...868
Checking And Replacement Of Connecting Rod Bearings...869
Checking And Replacement Of Piston Pin Bushing...870
Checking Cylinders...870
Checking And Measuring Pistons...870
Repair Of Cylinder Head...871
Repair Of Rocker Arms...874
Repair Of Cooling Air Blower...874
Removing And Installing A Fuel Injection Nozzle...875
GENERAL ENGINE DATA (F2L410)...876
Torque Specifications (Deutz Engine)...876
FITS, CLEARANCES, ADJUSTMENTS – DEUTZ ENGINE...877
Oil System...877
Fuel System...877
Governor, Front Cover and Throttle...877
Cylinder Head and Valves...877
Cylinder and Piston...877
Camshaft, Crankshaft, Bearings...878
SPECIAL TOOLS...878
Mainframe & Hydraulics...878
Deutz Engine Tools...878
PETTER ENGINE SERVICE...880
ENGINE DISASSEMBLY AND REPAIR...882
Removal Of Connecting Rod...883
Removal Of Crankshaft...883
Removal Of Camshaft...884
Removal Of Oil Pump And Governor Assembly...885
Oil Filter...885
Lubricating Oil Pump...887
Installation Of Camshaft...888
Connecting Rod Assembly...889
Installation Of Cylinders And Pistons...889
Piston Assembly...890
Installation Of Cylinder Heads...890
Installation Of Valve Rocker Gear...891
Adjustment Of Valve Rockers...891
Adjustment Of Decompressor...891
Fuel Pump Installation...891
Fuel Filter Assembly...891
Fuel And Oil Filter Assembly...891
Timing The Engine...891
Injector Installation...892
TECHNICAL DATA (Fits, Clearances & Torques)...893
SPECIFICATIONS...894
ENGINE SPECIFICATIONS (WISCONSIN)...896
ENGINE SPECIFICATIONS (Wisconsin)...898
Fuel Specifications...898
Engine Oil...898
Specifications...898
Valve Mechanism...899
Crankshaft...899
Idler Gear...899
Connecting Rod...899
Piston, Piston Pin, Piston Rings...899
Ignition System...899
Distributor Advance Characteristics...899
Starter...899
Engine Torque Specifications...899
600 LOADER (WISCONSIN GAS)...900
OPERATIONAL & PERFORMANCE...900
ENGINE...900
LOADER HYDRAULICS...900
ELECTRICAL...900
DRIVE SYSTEM...900
CAPACITIES...900
COUNTERWEIGHT...900
MACHINE WEIGHT (Less Bucket)...900
610 LOADER (WISCONSIN GAS)...901
OPERATIONAL & PERFORMANCE...901
ENGINE...901
LOADER HYDRAULICS...901
ELECTRICAL...901
DRIVE SYSTEM...901
CAPACITIES...901
COUNTERWEIGHT...901
MACHINE WEIGHT (Less Attachments)...901
ENGINE SPECIFICATIONS (DEUTZ)...902
ENGINE SPECIFICATIONS (Deutz F2L 411)...904
Fuel System...904
Lubrication System...904
overn, Front Cover and Throttle...905
Cylinder Head and Valves...905
Cylinder, Piston and Connecting Rod...905
Camshaft, Crankshaft, Bearings...905
Torque Specifications...906
Special Tools...906
600D LOADER (DEUTZ DIESEL)...907
OPERATIONAL & PERFORMANCE...907
ENGINE...907
LOADER HYDRAULICS...907
ELECTRICAL...907
DRIVE SYSTEM...907
CAPACITIES...907
TIRES...907
COUNTERWEIGHT...907
MACHINE WEIGHT (Less Bucket)...907
611 LOADER (DEUTZ DIESEL)...908
OPERATIONAL & PERFORMANCE...908
ENGINE...908
LOADER HYDRAULICS...908
ELECTRICAL...908
DRIVE SYSTEM...908
CAPACITIES...908
TIRES...908
COUNTERWEIGHT...908
MACHINE WEIGHT (Less Bucket)...908
611D LOADER (BUREAU OF MINES APPROVED)...909
OPERATIONAL & PERFORMANCE...909
ENGINE...909
LOADER HYDRAULICS...909
ELECTRICAL...909
DRIVE SYSTEM...909
CAPACITIES...909
TIRES...909
COUNTERWEIGHT...909
MACHINE WEIGHT (Less Attachments)...909
ENGINE SPECIFICATIONS (PETTER)...910
ENGINE SPECIFICATIONS (Petter)...912
Fuel Specifications...912
Engine Oil...912
Specifications...912
Lubrication System...912
Cylinder Head...913
Valve Mechanism...913
Camshaft...913
Crankshaft...913
Crankshaft Regrinding Diameters...913
Connecting Rod...913
Piston...913
Cylinder Block...913
Torque Specifications...914
600D LOADER (DEUTZ DIESEL)...915
OPERATIONAL & PERFORMANCE...915
ENGINE...915
LOADER HYDRAULICS...915
ELECTRICAL...915
DRIVE SYSTEM...915
CAPACITIES...915
TIRES...915
COUNTERWEIGHT...915
MACHINE WEIGHT (Less Bucket)...915
MOTOR SPECIFICATIONS, (ELECTRIC)...916
600E LOADER (RELIANCE ELECTRIC)...918
OPERATIONAL & PERFORMANCE...918
MOTOR...918
LOADER HYDRAULICS...918
POWER TRAIN...918
CAPACITIES...918
TIRES...918
COUNTERWEIGHT...918
MACHINE WEIGHT (Less Attachment)...918
TECHNICAL DATA...920
LOADER TORQUE SPECIFICATIONS...922
Hydraulic Fluid...922
Special Tools...922
DECIMAL AND MILLIMETER EQUIVALENTS...923
U.S. TO METRIC CONVERSION...923
STANDARD TORQUE SPECIFICATIONS FOR BOLTS...924
ALPHABETICAL INDEX...928
SERVICE BULLETINS...928
019...930
042...932
SERVICE MANUAL REVISIONS...930
600-002...934
600-003...936
6556520 (3-87) - 444, 500, 600 Service Manual Supplement...938
MAINTENANCE SAFETY...940
CONTENTS...942
FOREWORD...942
HYDRAULIC SYSTEM...944
HYDRAULIC SYSTEM...946
CHANGING AND ADDING HYDRAULIC OIL...946
DRAINING CONDENSATION...946
DESCRIPTION OF HYDRAULIC CIRCUIT...946
OIL FILTRATION...946
TUBLINES, HOSES, FITTING...947
37° Flare Connection...947
Straight Thread O-Ring Fitting (Elbow, Adapter, Etc.)...947
Pipe Thread Fittings...947
Tubelines and Hoses...947
HYDRAULIC SYSTEM (444 & 500)...948
CHANGING HYDRAULIC OIL FILTER ELEMENT...948
CHECKING THE OVERALL CONDITION OF HYDRAULIC SYSTEM...951
CHANGING MASTER RELIEF SETTING...953
CARTRIDGE RELIEF PRESSURE SETTING...953
VARIABLE SPEED VALVE...953
VARIABLE SPEED CHECK (LOCK) VALVE...954
CLUTCH PRESSURE RELIEF VALVE...955
CONTROL VALVE SEAL REPLACEMENT...955
HYDRAULIC PUMP REPAIR (Webster Pump)...958
HYDRAULIC CYLINDER REPAIR...960
HYDRAULIC PUMP ALIGNMENT (M–500 and M–444 Gasoline or LP Gas)...961
ELECTRICAL SYSTEM...962
ALTERNATOR CHARGE SYSTEM (500, 600)...964
Installation of Equipment Solenoids...966
Rectifier–Regulator Mounting...966
Flywheel Alternator System...966
Servicing the Alternator System...967
CHECKING THE RECTIFIER AND REGULATOR...970
STATOR CHECKS...971
ENGINE SERVICE...976
WISCONSIN ENGINE SERVICE (M–600)...978
RESTORING COMPRESSION...978
GOVERNOR ADJUSTMENT...978
STORAGE OF ENGINES...978
RETURNING STORED ENGINE TO SERVICE...979
CARBURETOR ADJUSTMENT...979
CARBURETOR RECONDITIONING...979
LPG CARBURETOR SERVICE...983
VAPORIZER – PRIMARY REGULATOR SERVICE...984
SECONDARY REGULATOR SERVICE...986
LP FUEL FILTER LOCK...988
IGNITION TIMING...988
DISTRIBUTOR MAINTENANCE...989
SPARK PLUG...989
HIGH TEMPERATURE SAFETY SWITCH...989
ENGINE RECONDITIONING...990
ACCESSORIES...990
FLYWHEEL...990
AIR SHROUDING...990
CARBURETOR & MANIFOLDS...990
CYLINDER HEAD...990
GEAR COVER...991
CAMSHAFT GEAR...991
IDLER GEAR AND SHAFT...991
OIL PAN...991
OIL PUMP...991
PISTONS AND CONNECTING RODS...991
PISTON RINGS...992
CYLINDER BLOCKS...992
VALVES & SEAT INSERTS...993
CRANKSHAFT...994
CAMSHAFT...994
VALVE TAPPETS...994
TECHNICAL DATA (Wisconsin)...995
FITS & CLEARANCES...995
TORQUE VALUES...995
Untitled...996
ONAN ENGINE SERVICE (444)...1000
ENGINE OIL...1000
CRANKCASE BREATHER...1000
GOVERNOR & SPEED CONTROL...1000
CARBURETOR ADJUSTMENT...1000
CARBURETOR RECONDITIONING (Gasoline)...1000
FUEL PUMP...1001
CARBURETOR RECONDITIONING (LP Gas)...1001
VAPORIZER – PRIMARY REGULATOR SERVICE...1002
VALVE SYSTEM...1003
TAPPET ADJUSTMENT...1003
IGNITION TIMING...1004
SPARK PLUGS...1004
ENGINE RECONDITIONING...1006
TECHNICAL DATA (Onan)...1011
FITS & CLEARANCES...1011
TORQUE VALUES...1011
KOHLER ENGINE SERVICE (500)...1014
ENGINE OIL...1014
COMPRESSION CHECK...1014
CRANKCASE BREATHER...1014
GOVERNOR & SPEED CONTROL...1014
CARBURETOR ADJUSTMENT...1015
CARBURETOR RECONDITIONING...1015
ELECTRIC FUEL PUMP SERVICE...1018
CARBURETOR ADJUSTMENTS (LPG)...1018
CARBURETOR RECONDITIONING (LP Gas)...1019
VAPORIZER–PRIMARY REGULATOR SERVICE...1021
IGNITION TIMING...1022
USING TIMING LIGHT...1022
MAGNETO SERVICE...1022
ELECTRICAL SYSTEM...1023
ENGINE RECONDITIONING...1026
TECHNICAL DATA (Kohler)...1034
RUNNING CLEARANCES...1034
OIL PUMP...1034
MAGNETO IGNITION...1034
TORQUE VALUES...1035
SERVICE MANUAL REVISIONS...1036
600-01...1036
6556520 (6-12) - 444, 500, 600 Service Manual Supplement...1038
MAINTENANCE SAFETY...1040
CONTENTS...1042
FOREWORD...1042
HYDRAULIC SYSTEM...1044
HYDRAULIC SYSTEM...1046
CHANGING AND ADDING HYDRAULIC OIL...1046
DRAINING CONDENSATION...1046
DESCRIPTION OF HYDRAULIC CIRCUIT...1046
OIL FILTRATION...1046
TUBLINES, HOSES, FITTING...1047
37° Flare Connection...1047
Straight Thread O-Ring Fitting (Elbow, Adapter, Etc.)...1047
Pipe Thread Fittings...1047
Tubelines and Hoses...1047
HYDRAULIC SYSTEM (444 & 500)...1048
CHANGING HYDRAULIC OIL FILTER ELEMENT...1048
CHECKING THE OVERALL CONDITION OF HYDRAULIC SYSTEM...1051
CHANGING MASTER RELIEF SETTING...1053
CARTRIDGE RELIEF PRESSURE SETTING...1053
VARIABLE SPEED VALVE...1053
VARIABLE SPEED CHECK (LOCK) VALVE...1054
CLUTCH PRESSURE RELIEF VALVE...1055
CONTROL VALVE SEAL REPLACEMENT...1055
HYDRAULIC PUMP REPAIR (Webster Pump)...1058
HYDRAULIC CYLINDER REPAIR...1060
HYDRAULIC PUMP ALIGNMENT (M–500 and M–444 Gasoline or LP Gas)...1061
ELECTRICAL SYSTEM...1062
ALTERNATOR CHARGE SYSTEM (500, 600)...1064
Installation of Equipment Solenoids...1066
Rectifier–Regulator Mounting...1066
Flywheel Alternator System...1066
Servicing the Alternator System...1067
CHECKING THE RECTIFIER AND REGULATOR...1070
STATOR CHECKS...1071
ENGINE SERVICE...1076
WISCONSIN ENGINE SERVICE (M–600)...1078
RESTORING COMPRESSION...1078
GOVERNOR ADJUSTMENT...1078
STORAGE OF ENGINES...1078
RETURNING STORED ENGINE TO SERVICE...1079
CARBURETOR ADJUSTMENT...1079
CARBURETOR RECONDITIONING...1079
LPG CARBURETOR SERVICE...1083
VAPORIZER – PRIMARY REGULATOR SERVICE...1084
SECONDARY REGULATOR SERVICE...1086
LP FUEL FILTER LOCK...1088
IGNITION TIMING...1088
DISTRIBUTOR MAINTENANCE...1089
SPARK PLUG...1089
HIGH TEMPERATURE SAFETY SWITCH...1089
ENGINE RECONDITIONING...1090
ACCESSORIES...1090
FLYWHEEL...1090
AIR SHROUDING...1090
CARBURETOR & MANIFOLDS...1090
CYLINDER HEAD...1090
GEAR COVER...1091
CAMSHAFT GEAR...1091
IDLER GEAR AND SHAFT...1091
OIL PAN...1091
OIL PUMP...1091
PISTONS AND CONNECTING RODS...1091
PISTON RINGS...1092
CYLINDER BLOCKS...1092
VALVES & SEAT INSERTS...1093
CRANKSHAFT...1094
CAMSHAFT...1094
VALVE TAPPETS...1094
TECHNICAL DATA (Wisconsin)...1095
FITS & CLEARANCES...1095
TORQUE VALUES...1095
Untitled...1096
ONAN ENGINE SERVICE (444)...1100
ENGINE OIL...1100
CRANKCASE BREATHER...1100
GOVERNOR & SPEED CONTROL...1100
CARBURETOR ADJUSTMENT...1100
CARBURETOR RECONDITIONING (Gasoline)...1100
FUEL PUMP...1101
CARBURETOR RECONDITIONING (LP Gas)...1101
VAPORIZER – PRIMARY REGULATOR SERVICE...1102
VALVE SYSTEM...1103
TAPPET ADJUSTMENT...1103
IGNITION TIMING...1104
SPARK PLUGS...1104
ENGINE RECONDITIONING...1106
TECHNICAL DATA (Onan)...1111
FITS & CLEARANCES...1111
TORQUE VALUES...1111
KOHLER ENGINE SERVICE (500)...1114
ENGINE OIL...1114
COMPRESSION CHECK...1114
CRANKCASE BREATHER...1114
GOVERNOR & SPEED CONTROL...1114
CARBURETOR ADJUSTMENT...1115
CARBURETOR RECONDITIONING...1115
ELECTRIC FUEL PUMP SERVICE...1118
CARBURETOR ADJUSTMENTS (LPG)...1118
CARBURETOR RECONDITIONING (LP Gas)...1119
VAPORIZER–PRIMARY REGULATOR SERVICE...1121
IGNITION TIMING...1122
USING TIMING LIGHT...1122
MAGNETO SERVICE...1122
ELECTRICAL SYSTEM...1123
ENGINE RECONDITIONING...1126
TECHNICAL DATA (Kohler)...1134
RUNNING CLEARANCES...1134
OIL PUMP...1134
MAGNETO IGNITION...1134
TORQUE VALUES...1135
SERVICE MANUAL REVISIONS...1136
600-01...1136
600-02...1138
6556602 - M444, M500, M600, M610 Service Manual...1140
Supplement to 6556276 - 444, 500, 600 Service Manual Supplement...1318
Bobcat Loaders M444, M500, M600, 600, 600D, 610, M610, 611, 620 Repair Service Manuals
