Bobcat 630, 631, 632 Skid-Steer Loader Repair Service Manual – 6556454

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This workshop repair service manual PDF download for the 630, 631, 632 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Loader 630
Bobcat Loader 631
Bobcat Loader 632

TABLE OF CONTENTS :

PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
TECHNICAL DATA
ALPHABETICAL INDEX
SERVICE MANUAL REVISIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6556454 (2–87)
Total Pages : 284

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MAINTENANCE SAFETY
CONTENTS
FOREWORD

PREVENTIVE MAINTENANCE
INTRODUCTION
Symbols
Serial Number Identification
Loader Serial Number
Engine Serial Number
Pre–Delivery Inspection
30 Hour Inspection
SERVICE INTERVALS
BOBCAT SERVICE SCHEDULE*
ENGINE SERVICE
Engine Oil And Filter
Checking Oil
Adding Oil
Replacement Oil And Filter
Crankcase Breather
Air Cleaner System
Fuel System (630, 632)
Fuel Filter
Fuel System (631)
Fuel Pump
Carburetor
Carburetor Adjustment
Idle Adjusting Needle
Throttle Idle Adjustment
Fuel Shut–Off
Engine Cooling System
Removing Coolant From System (632)
Engine Electrical System (630, 631 & 632)
Using An Extra Battery
Installing New Battery
Ignition System (630 & 632)
Making Adjustment of Spark Plug Gap
Making Adjustment of Point Gap
HYDRAULIC FLUID AND FILTER
Fluid
Filter
TRANSMISSION AND DRIVE SYSTEM
Drive Chains
Brakes
Fluid
Tires
Tire Rotation
LOADER LUBRICATION
BOB–TACH AND PIVOT PINS
THE ENGINE MUFFLER

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC CIRCUIT
HYDRAULIC SYSTEM INFORMATION
Keeping Bobcat Clean
37° Flare Connections
Tubelines And Hoses
Straight Thread O–Ring Connections
HYDRAULIC TROUBLESHOOTING
CONTROL VALVE
Removing Control Valve
Disassembly And Inspection Of Control Valve
Assembling Control Valve
Detent Spool Repair (Lift And Auxiliary Spools)
Relief Valve
Check Release Pressure
Relief Valve Removal and Replacement
Check Output of the Hydraulic Pump
HYDRAULIC PUMP
Checking Output Of Pump
Hydraulic Pump Replacement
HYDRAULIC CYLINDERS
Checking Lift Cylinders
Checking Tilt Cylinder
Removing Hydraulic Cylinder
Hydraulic Cylinder Repair
Disassembly
Assembly
Tilt Cylinder Spacer (3’’ Tilt Cylinder)
QUICK COUPLERS
Restriction in the Quick Couplers (Early Models Only)

HYDROSTATIC SYSTEM
HYDROSTATIC CIRCUIT
HYDROSTATIC TROUBLESHOOTING
STEERING LINKAGE ADJUSTMENT
REPLENISHING VALVE
Checking Replenishing Valves
BY–PASS VALVE
PUMP ASSEMBLY – REMOVAL AND INSTALLATION
Removing the Bronze Filter
HYDROSTATIC PUMP ASSEMBLY – REPAIR
Hydrostatic Pump Disassembly
Hydrostatic Pump Inspection
Yoke, Pintle Bearing, etc. – Installation
#2 Pump Assembly
Assemble Rotating Group
Installing Rotating Group Into Housing
#1 Pump Assembly
Assemble Rotating Group
Install Rotating Group Into Housing
Installing Pumps to Manifold Block
HYDROSTATIC MOTORS (630 S/N 15375 & Below and 632 S/N 15320 & Below)
Removing The Hydrostatic Motors
Installing Hydrostatic Motors
Making The Special Tool For Holding Motor Sprockets
Hose Location
To Remove Air From The Hydrostatic System (S/N 12999 & Below)
To Remove Air From The Hydrostatic System (S/N 13000 & Above)
HYDROSTATIC MOTOR REPAIR (630 (S/N 15375 & Below) And 632 (S/N 15320 & Below)
Hydrostatic Motor Disassembly and Inspection
Hydrostatic Motor Assembly
Start–Up Procedure For The Hydrostatic Motor
HYDROSTATIC MOTOR REPAIR (630 – S/N 15376 & Above, 631 and 632 – S/N 15321 & Above)
Disassembly Of The Hydrostatic Motor
Hydrostatic Motor Inspection
Assembly Of The Hydrostatic Motor
Installing The Hydrostatic Motor
Start–Up Procedure For The Hydrostatic Motor
STEERING CONTROLS
Installing Steering Linkages – 630–S/N 15300 & Below; 631–S/N 12253 & Below; 632–S/N 15450 & Below;
Installing Steering Linkages; 630 (S/N 15301 & Above; 631 (S/N 12254 & Above); 632 (S/N 15451 & Above)

DRIVE SYSTEM
FINAL DRIVE
Drive Chains
AXLE AND BEARINGS
Axle Bearing Removal
Assembly And Installation
BRAKE INSTALLATION

MAIN FRAME
ROPS REMOVAL AND INSTALLATION
PIVOT PIN REPLACEMENT ON THE LIFT ARMS
BOB–TACH
Checking Bob–Tach Wedges
Bob–Tach Removal
Bob–Tach Installation
Bob–Tach Pins
Bob–Tach Over–Center Stop
MAIN FRAME TO UPRIGHT FRAME BOLTS
LIFT ARMS

ELECTRICAL SYSTEM
USING AN EXTRA BATTERY
ROPS ELECTRICAL SYSTEM (Harness P/N 6558859)
ROPS WIRING DIAGRAM (Harness P/N 6557492)
630 ENGINE ELECTRICAL SYSTEM (S/N 14999 & Below) (Harness P/N 6558862)
ENGINE WIRING DIAGRAM 630 (S/N 14999 & Below) (Harness P/N 6558862)
ENGINE ELECTRICAL SYSTEM 631 (S/N 4997 12999 & Below)
ENGINE WIRING DIAGRAM 631 (S/N 4997 12999 & Below)
ENGINE ELECTRICAL SYSTEM
ENGINE WIRING DIAGRAM
ELECTRICAL GENERAL INFORMATION
Troubleshooting The Flywheel Alternator (630)
PROBLEM: BATTERY OVERCHARGE
PROBLEM: LOW/NO CHARGE
To Check The Stator
To Check the Rectifier Module
To Check the Regulator Module
ELECTRICAL CIRCUIT (631, 632)
Electrical Troubleshooting
CHART A BATTERY HAS LOW CHARGE
CHART B BATTERY OVER–CHARGE
ROPS Electrical Connector
ALTERNATOR BELT ADJUSTMENT AND REPLACEMENT (631, 632)
Adjustment
Replacement
Check Condition of Battery And Cables
Check Alternator Wiring
Check Alternator Output
Check Regulator
ALTERNATOR SERVICE
Alternator Removal
Alternator Disassembly
Checking Rotor
Checking Diode Trio
Checking Rectifier
Alternator Assembly and Installation
STARTER
Checking Starter
Removing Starter
Starter Disassembly
Starter Cleaning and Inspection
Brush Replacement
Starter Assembly
Check Electrical Wiring

ENGINE SERVICE
WISCONSIN ENGINE (630)
TROUBLESHOOTING
ENGINE IGNITION SYSTEM
Distributor Maintenance
Timing Procedure
Spark Plugs
CARBURETOR SERVICE
Adjustments
Float Adjustment
Governor Adjustment
REMOVAL OF ENGINE
REMOVAL OF ACCESSORIES
REMOVAL OF FLYWHEEL
REMOVAL OF AIR HOUSING
REMOVAL OF CARBURETOR AND MANIFOLD
REMOVAL OF CYLINDER HEADS
REMOVAL OF CAMSHAFT
REMOVAL OF IDLER GEAR AND SHAFT
REMOVAL OF OIL PAN
REMOVAL OF OIL PUMP
REMOVAL OF PISTONS AND CONNECTING RODS
REMOVAL OF VALVE AND SEAT INSERTS
REMOVAL OF CYLINDER BLOCK
REMOVAL OF CRANKSHAFT
REMOVAL OF CAMSHAFT
REMOVAL OF VALVE TAPPETS
INSTALLATION OF VALVE TAPPETS
INSTALLATION OF CAMSHAFT
INSTALLATION OF CRANKSHAFT
Three Bearing Crankshaft
INSTALLATION OF CYLINDER BLOCKS
INSTALLATION OF PISTON RINGS
INSTALLATION OF VALVES AND SEAT INSERTS
INSTALLATION OF PISTONS AND CONNECTING RODS
INSTALLATION OF OIL PUMP
OIL PAN INSTALLATION
INSTALLATION OF IDLER GEAR AND SHAFT
INSTALLATION OF GEAR COVER
INSTALLATION OF CYLINDER HEAD
INSTALLATION OF CARBURETOR AND MANIFOLD ASSEMBLY
INSTALLATION OF AIR HOUSING
INSTALLATION OF FLYWHEEL
INSTALLATION OF ACCESSORIES
GOVERNOR SERVICE
DEUTZ ENGINE–FL411D (631)
TROUBLESHOOTING
Engine Mounts
FUEL SYSTEM
Fuel And Control Linkage Adjustment
Venting Air From Fuel System
Fuel Filter
Fuel Lift Pump
Fuel Injection Pump Checking
Removal Of Fuel Injection Pump
Fuel Injection Pump Service
To Install Fuel Injection Pump
Adjustment Of Fuel Delivery
FUEL INJECTION NOZZLES
Removal Of Fuel Injection Nozzles
Disassembly & Repair Of Fuel Injection Nozzles
Installation Of Fuel Injection Nozzles
ENGINE INFORMATION
ENGINE REMOVAL
BLOWER FAN
Removal
Installation
Disassembly
Assembly
CYLINDER HEAD AND VALVES
Removal
Disassembly
Repair and Assembly
Installation Of Cylinder Head
CYLINDERS, PISTONS, CONNECTING RODS
Assembly
OIL PUMP, FILTER HOUSING AND RELIEF VALVE
Oil Pump Removal
Installation
Oil Pressure Relief Valve
Filter Housing
ENGINE FRONT COVER
Removal
Disassembly & Inspection
Assembly
Installation
GOVERNOR
Removal and Disassembly
Assembly and Installation
CAMSHAFT (Engine Must Be Removed)
Removal
Installation
Crankshaft Removal
Crankshaft Inspection
Crankshaft Assembly
FLYWHEEL
DEUTZ ENGINE–F2L511 (631)
TROUBLESHOOTING
ENGINE MOUNTS
FUEL SYSTEM
Venting Air From Fuel System
Fuel Filters
Fuel Lift Pump
Removal Of Fuel Injection Pump
Removal Of Injection Pump
Fuel Injection Pump Service
To Install Fuel Injection Pump
Adjustment Of Fuel Delivery
FUEL INJECTION NOZZLES
Removal
Disassembly And Repair Of Injector (In Shop)
Installation Of Injector
ENGINE INFORMATION
ENGINE REMOVAL
BLOWER FAN
Removal Of Blower Fan
Installation
Disassembly
Assembly
CYLINDER HEAD AND VALVES
Removal And Disassembly
Repair And Assembly
Checking Piston Crown Clearance And Installation Of Cylinder Head
CYLINDER, PISTONS AND CONNECTING RODS
Assembly
OIL PUMP, FILTER HOUSING AND RELIEF VALVE
Oil Pump Removal
Installation
Oil Pressure Relief Valve
ENGINE FRONT COVER
Removal
Disassembly And Inspection
Assembly
Installation
GOVERNOR
Removal And Disassembly
Assembly And Installation
CAMSHAFT (Engine Must Be Out Of Machine)
Removal
Installation
Crankshaft Removal
Crankshaft Inspection
Crankshaft Assembly
FLYWHEEL
Installing Flywheel
ENGINE OIL COOLER
FORD ENGINE (632)
TROUBLESHOOTING
CHECKS AND ADJUSTMENTS
Engine Oil Pressure
Valve Clearance
Checking Engine Compression
Understanding The Results Of The Test
Carburetor, Throttle And Governor Adjustments
Ignition System
Coil To Coil Ground Voltmeter Test
Spark Plug Wires Resistance Test
Spark Plug Test
Distributor Tests
Dwell Angle Check
Spark Strength Tests
Ignition System Tests
Battery To Coil Voltmeter Test
Starting Ignition Circuit Voltmeter Test
Breaker Point Gap Adjustment
Ignition Timing
Timing Mark Locations
Initial Ignition Timing
CARBURETOR REPAIR
ENGINE DIAGNOSIS AND TESTING
Camshaft Lobe Lift
Crankshaft End Play
Flywheel Face Alignment Check
Camshaft End Play
ENGINE OVERHAUL
Cylinder Head
Valve Guides
Grinding Valve Seats
Valves
Grinding Valves
Select Fitting Of Valves
Camshaft Repair
Crankshaft
Reconditioning Crankshaft Journals
To Check Crankshaft Or Connecting Rod Bearings With Plastigage
Pistons, Pins And Rings
To Install Pistons
To Install Piston Rings
Installing Piston Pins
Valve Rocker Arm And/Or Shaft Assembly
Push Rods
Cylinder Block
Finishing Cylinder Walls
Cylinder Head
Cleaning
Inspection
Tappets
Cleaning
Inspection
Camshaft
Cleaning and Inspection
Crankshaft Inspection
Flywheel Inspection
Connecting Rods
Cleaning
Inspection
Pistons, Pins And Rings
Cleaning
Inspection
Main And Connecting Rod Bearings
Cleaning
Inspection
Cylinder Block
Cleaning
Inspection
OIL PUMP
Cleaning
Inspection
REMOVAL OF ENGINE
VALVE ROCKER ARM COVER, ROCKER ARM AND/OR SHAFT
Removal And Disassembly
Installation
VALVE PUSHROD
Removal
Installation
INTAKE MANIFOLD
Removal
Installation
CYLINDER HEAD
Removal
Installation
VALVE SPRING, RETAINER AND STEM SEAL (CYLINDER HEAD REMOVED)
Removal
Installation
VALVE SPRING, RETAINER AND STEM SEAL (CYLINDER HEAD INSTALLED)
Removal
Installation
WATER PUMP
Removal
Installation
ENGINE FRONT COVER, TIMING CHAIN AND CRANKSHAFT SPROCKETS
Installation
Removal
Remove Timing Cover
FRONT OIL SEAL
Removal
Installation
TIMING CHAIN TIGHTENER
Removal
Installation
CAMSHAFT AND VALVE LIFTERS
Removal
Installation
FLYWHEEL RING GEAR
Removal
Installation
OIL PAN
Removal
Installation
OIL PUMP
Removal
Installation
CRANKSHAFT REAR OIL SEAL
Removal
Installation
MAIN BEARINGS
Removal
Installation
CONNECTING ROD BEARINGS
Removal
Installation
PISTONS AND CONNECTING RODS
Removal
Installation
CRANKSHAFT
Removal
Installation
CAMSHAFT BEARINGS
Removal of Camshaft
Installation

TECHNICAL DATA
ENGINE SPECIFICATIONS, 630 (WISCONSIN)
630 LOADER SPECIFICATIONS
OPERATIONAL & PERFORMANCE
ENGINE
LOADER HYDRAULICS
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
MACHINE WEIGHT
ENGINE SPECIFICATIONS, 630 (Wisconsin)
Fuel Specifications
Engine Oil
Valve Mechanism
Crankshaft
Idler Gear
Connecting Rod
Piston, Piston Pin, Piston Rings
Ignition System
Distributor Advance Characteristics
Starter
Engine Torque Specifications
ENGINE SPECIFICATIONS, 631 (DEUTZ)
631 LOADER SPECIFICATIONS
OPERATIONAL & PERFORMANCE
ENGINE
LOADER HYDRAULICS
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
MACHINE WEIGHT
ENGINE SPECIFICATIONS – F2L411D, 631 (Deutz)
Fuel System
Governor, Front Cover And Throttle
Cylinder Head And Valves
Cylinder, Piston And Connecting Rod
Camshaft, Crankshaft, Bearings
Lubrication System
Torque Specifications (Deutz Engine)
Special Tools (Deutz)
ENGINE SPECIFICATIONS – F2L511, 631 (Deutz)
Fuel System
Governor, Front Cover And Throttle
Cylinder Head And Valves
Cylinder, Piston And Connecting Rod
Camshaft, Crankshaft, Bearings
Lubrication System
Torque Specifications
Special Tools (F2L511 Deutz)
ENGINE SPECIFICATIONS, 632 (FORD)
632 LOADER SPECIFICATIONS
OPERATIONAL & PERFORMANCE
ENGINE
LOADER HYDRAULICS
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
MACHINE WEIGHT
ENGINE SPECIFICATIONS, 632 (FORD)
Fuel Specifications
Fuel System
Engine Oil
Lubrication System
Cylinder Heads
Valve Mechanism
Camshaft
Crankshaft
Connecting Rod
Piston
Piston Pin
Piston Rings
Cylinder Block
Ignition System
Starter
Torque Specifications For Engine
Special Tools (Ford)
Carburetor Tool
TECHNICAL DATA
LOADER TORQUE SPECIFICATIONS
HYDRAULIC/HYDROSTATIC TRANSMISSION FLUID
Hydrostatic System Specifications
SPECIAL TOOLS
Main Frame & Hydraulic Tools
Hydrostatic System Tools
CONVERSIONS
U.S. To Metric Conversion
Decimal And Millimeter Equivalents

ALPHABETICAL INDEX

SERVICE MANUAL REVISIONS
630–1
630–2
630–3
630–4

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