Bobcat 600, 600D, 610, 611 Skid-Steer Loader Repair Service Manual - 6556276

-
This workshop repair service manual PDF download for the 600, 600D, 610, 611 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 600
Bobcat Loader 600D
Bobcat Loader 610
Bobcat Loader 611 


TABLE OF CONTENTS :

GENERAL SERVICE
TROUBLESHOOTING
DRIVE SYSTEM
HYDRAULIC SYSTEM
WISCONSIN ENGINE SERVICE
DEUTZ ENGINE SERVICE
PETTER ENGINE SERVICE
SPECIFICATIONS
ALPHABETICAL INDEX
SERVICE BULLETINS
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6556276 (6–87)
Total Pages : 214


This Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

-

MAINTENANCE SAFETY
CONTENTS
    FOREWORD
    
GENERAL SERVICE
    SERVICE SCHEDULE
    TIRES
    LOADER LUBRICATION
    CHANGING AND ADDING HYDRAULIC OIL
    REMOVING WATER FROM HYDRAULIC TANKS
    BOB–TACH FRAME
    HYDRAULIC FLUID FILTERCHANGE
    ENGINE AIR CLEANER
    OIL TYPE AIR CLEANER
    HEAVY DUTY AIR CLEANER
    ENGINE OIL
    OIL SPECIFICATIONS FOR ENGINES
    ENGINE OIL FILTER (Wisconsin)
    ENGINE OIL FILTER (Duetz Diesel)
    OIL FILTER (Petter)
    CRANKCASE AIR VENT (Wisconsin)
    CRANKCASE AIR VENT (Deutz)
    FUEL SPECIFICATIONS
    FUEL FILTER
    EXCESS FUEL LEVER ADJUSTMENT (Deutz Engine)
    FUEL PUMP (Wisconsin)
    FUEL ADJUSTMENT (Petter)
    ENGINE COOLING SYSTEM
    WATER SCRUBBER MUFFLER (600 Diesel)
    IGNITION TIMING (Wisconsin Engine)
    DISTRIBUTOR MAINTENANCE (Wisconsin)
    SPARK PLUG (Wisconsin)
    ELECTRICAL SYSTEMS
        CHECKING REGULATOR AND RECTIFIER
        STATOR CHECKS
        ALTERNATOR CHECK
        REGULATOR CHECK #1
        REGULATOR CHECK #2
        REGULATOR CHECK #3
        
TROUBLESHOOTING
    TROUBLESHOOTING THE DRIVE SYSTEM
    TROUBLESHOOTING THE HYDRAULIC SYSTEM
    TROUBLESHOOTING THE ENGINE
    
DRIVE SYSTEM
    CLUTCH ADJUSTMENT
        Adjustment Procedure
        Steering Clutch Adjustment
    DISASSEMBLY & ASSEMBLY
        Disassembly
        Assembly
    INSTALLING CLUTCH NEEDLE BEARINGS.
    DRIVE BELT INSTALLATION (Split Shaft)
    REMOVAL OF DRIVEN SHEAVE
    INSTALLING OF DRIVEN SHEAVE
    DRIVEN SHEAVE DISASSEMBLY
    ASSEMBLY OF DRIVEN SHEAVE (TAPERED JACKSHAFT)
    DISASSEMBLY OF DRIVE SHEAVE (STRAIGHT JACKSHAFT)
    ASSEMBLY OF DRIVEN SHEAVE (STRAIGHT JACKSHAFT)
    DRIVEN SHEAVE ALIGNMENT
    JACKSHAFT BEARING INSTALLATION
    REMOVAL OF VARIABLE DRIVE SHEAVE WITH ROTO SWIVEL INSIDE (600, 610 Gasoline and Diesel, Serial Number 72319 and Up)
    ROTO–SWIVEL DISASSEMBLY
    ROTO–SWIVEL ASSEMBLY
    ASSEMBLY PROCEDURES FOR 610 VARIABLE SPEED WITH ROTO–SWIVEL INSIDE
    REMOVAL OF VARIABLE SHEAVE WITH ROTO–SWIVEL OUTSIDE (600 Gasoline, LP and Diesel; Serial Number 67253–72318)
    REMOVAL OF FRAME SUPPORT VARIABLE SHEAVE (600 Gasoline and LP; serial Number 62796–67252)
    AXLE REMOVAL (FRONT AXLE)
    AXLE BEARING AND SEAL INSTALLATION
    INSTALLATION OF AXLE
    AXLE SPROCKET REMOVAL & INSTALLATION
    LOWER JACKSHAFT REMOVAL
    LOWER JACKSHAFT SPROCKET REPAIR
    LOWER JACKSHAFT INSTALLATION
    DRIVE CHAIN ADJUSTMENT
    BRAKE ASSEMBLY
    ASSEMBLY OF BRAKE
    BRAKE ADJUSTMENT
    
HYDRAULIC SYSTEM
    HYDRAULIC SYSTEM
        Hydraulic Circuit Operation
        HYDRAULIC SYSTEM (600 Electric and 600 Diesel W/Petter Engine) (Hydraulic Flow)
        Hydraulic System (600, 610 Gasoline and LP Gas) (Hydraulic Fluid Flow)
        HYDRAULIC SYSTEM (600 and 610 Diesel W/Deutz Engine) (Hydraulic Flow)
    RESTRICTOR FOR TILT HYDRAULIC CIRCUIT (Grapple Operation Only)
    CHECKING THE CONDITION OF HYDRAULIC SYSTEM
    RECOMMENDED HYDRAULIC OILFLOW RATE
    CHECKING CONDITION OF HYDRAULIC PUMP
    CHECKING THE PRESSURE SETTING OF THE CARTRIDGE RELEASE (In Lift and Auxiliary Control Valve)
    MASTER RELEASE VALVE ADJUSTMENT
    CARTRIDGE RELEASE ADJUSTMENT
    CHECKING VARIABLE SPEED VALVE PRESSURE ADJUSTMENT (Variable Speed Swivel Couplings)
        Variable Speed Control Valve With Holding Pressure Release Valve
    CHECKING PRESSURE ADJUSTMENT (Variable Speed Control Valve with no Holding Pressure Valve )
    VARIABLE SPEED CLOSING PRESSURE ADJUSTMENT (Variable Speed Control Valve with or with no Holding Release Valve)
    VARIABLE SPEED HOLDING RELEASE PRESSURE SETTING (600 PSI [4137 kPa] Minimum)
    DISASSEMBLY OF VARIABLE SPEED CONTROL VALVE (Seal Replacement with Control Valve in the Bobcat)
    ASSEMBLY OF VARIABLE SPEED CONTROL VALVE, SEAL REPLACEMENT WITH CONTROL VALVE IN THE BOBCAT (With Holding Release Valve)
    CONTROL VALVE SEAL INSTALLATION
    INSTALLING VALVE SPOOL SEALS IN THE VARIABLE SPEED CONTROL VALVE
    HYDRAULIC PUMP SERVICE (Webster Pump)
    DISASSEMBLY
    ASSEMBLY OF HYDRAULIC PUMP (Webster Pump)
    HYDRAULIC PUMP DISASSEMBLY (Cessna Pump)
    HYDRAULIC PUMP ASSEMBLY (Cessna Pump)
    HYDRAULIC LIFT OR TILT CYLINDER DISASSEMBLY
    INSTALLATION OF CYLINDER SEALS
    HYDRAULIC CYLINDER ASSEMBLY 
    HYDRAULIC PUMP ALIGNMENT (500 ELECTRIC)
    HYDRAULIC PUMP ALIGNMENT (600 Wisconsin)
        37° Flare Connections
        Tubelines and Hoses
        Installing O–Rings
        
WISCONSIN ENGINE SERVICE
    RETURN OF NORMAL COMPRESSION
    GOVERNOR ADJUSTMENT
    STORAGE OF ENGINE
    RETURN STORED ENGINE TO SERVICE
    CARBURETOR ADJUSTMENT
    CARBURETOR RECONDITIONING 
    TO DISASSEMBLE THROTTLE BODY
    DISASSEMBLY OF THE FUEL BOWL
    O ASSEMBLE FUEL BOWL AND INTAKE ASSEMBLY
    TO ASSEMBLE THROTTLE BODY
    ASSEMBLY OF FUEL BOWL AND THROTTLE BODY
    LP CARBURETOR SERVICE
    CARBURETOR REMOVAL
    LP CARBURETOR RECONDITIONING
    DISASSEMBLY PROCEDURE LP CARBURETOR
    CLEANING AND INSPECTION
    ASSEMBLE LP CARBURETOR
    VAPORIZER & PRIMARY REGULATOR SERVICE
    DISASSEMBLING THE VAPORIZER
    TO ASSEMBLE THE VAPORIZER
    ADJUSTMENT OF VAPORIZER
    LP FUEL FILTER LOCK–OFF
    FUEL FILTER LOCK–OFF DISASSEMBLY
    ENGINE RECONDITIONING
    REMOVAL OF ENGINE
    REMOVAL OF ACCESSORIES
    REMOVAL OF FLYWHEEL
    REMOVAL OF AIR HOUSING
    REMOVAL OF CARBURETOR AND MANIFOLD
    REMOVAL OF CYLINDER HEAD
    REMOVAL OF GEAR COVER
    REMOVAL OF CAMSHAFT
    REMOVAL OF IDLER GEARAND SHAFT
    REMOVAL OF OIL PAN
    REMOVAL OF OIL PUMP
    REMOVAL OF PISTONS AND CONNECTING RODS
    REMOVAL OF VALVES AND SEAT INSERTS
    REMOVAL OF CYLINDER BLOCK
    REMOVAL OF CRANKSHAFT
    REMOVAL OF CAMSHAFT
    REMOVAL OF VALVE TAPPET
    ASSEMBLY OF ENGINE AFTER RECONDITIONING INSTALLATION OF VALVE TAPPETS
    INSTALLATION OF CAMSHAFT
    INSTALLATION OF CRANKSHAFT
    INSTALLATION OF VALVES AND SEAT INSERTS
    INSTALLATION OF CYLINDER BLOCKS
    INSTALLATION OF PISTON RINGS
    INSTALLATION OF PISTONS AND CONNECTING RODS
    INSTALLATION OF OIL PUMP
    OIL PAN INSTALLATION
    INSTALLATION OF IDLER GEAR AND SHAFT
    INSTALLATION OF CAMSHAFT GEAR
    INSTALLATION OF GEAR COVER
    INSTALLATION OF CYLINDER HEAD
    INSTALLATION OF CARBURETOR AND MANIFOLD ASSEMBLY
    INSTALLATION OF AIR HOUSING
    INSTALLATION OF FLYWHEEL
    INSTALLATION OF ACCESSORIES
    
DEUTZ ENGINE SERVICE
    INSTRUCTIONS FOR TIGHTENING BOLTS AND STUDS
    CHECK AND ADJUSTMENTS
        Adjustment of Valve Clearance
        Compression Check
        Checking Fuel System
        Checking Fuel Injection Pump
        To Find top Dead Center And Start Of Fuel Injection
        Adjustment Of Start Of Fuel Injection
    ENGINE RECONDITIONING
    TO ASSEMBLE THE ENGINE
    INSPECTION AND REPAIR
        Checking The Crankshaft
        Reconditioning Crankshaft
        Checking Crankcase
        Checking And Installing Main Bearing
        Checking And Installing Camshaft And Bearings
        Checking The Oil Pump
        Installing A New Gear Starter Ring On Flywheel
        Checking Front Cover And Repair Of Engine Governor
        Check and Repair Of The Governor
        Checking And Replacement Of Connecting Rod Bearings
        Checking And Replacement Of Piston Pin Bushing
        Checking Cylinders
        Checking And Measuring Pistons
        Repair Of Cylinder Head
        Repair Of Rocker Arms
        Repair Of Cooling Air Blower
        Removing And Installing A Fuel Injection Nozzle
    GENERAL ENGINE DATA (F2L410)
        Torque Specifications (Deutz Engine)
    FITS, CLEARANCES, ADJUSTMENTS – DEUTZ ENGINE
        Oil System
        Fuel System
        Governor, Front Cover and Throttle
        Cylinder Head and Valves
        Cylinder and Piston
        Camshaft, Crankshaft, Bearings
    SPECIAL TOOLS
        Mainframe & Hydraulics
        Deutz Engine Tools
        
PETTER ENGINE SERVICE
    ENGINE DISASSEMBLY AND REPAIR
        Removal Of Connecting Rod
        Removal Of Crankshaft
        Removal Of Camshaft
        Removal Of Oil Pump And Governor Assembly
        Oil Filter
        Lubricating Oil Pump
        Installation Of Camshaft
        Connecting Rod Assembly
        Installation Of Cylinders And Pistons
        Piston Assembly
        Installation Of Cylinder Heads
        Installation Of Valve Rocker Gear
        Adjustment Of Valve Rockers
        Adjustment Of Decompressor
        Fuel Pump Installation
        Fuel Filter Assembly
        Fuel And Oil Filter Assembly
        Timing The Engine
        Injector Installation
    TECHNICAL DATA (Fits, Clearances & Torques)
    
SPECIFICATIONS
    ENGINE SPECIFICATIONS (WISCONSIN)
        ENGINE SPECIFICATIONS (Wisconsin)
            Fuel Specifications
            Engine Oil
            Specifications
            Valve Mechanism
            Crankshaft
            Idler Gear
            Connecting Rod
            Piston, Piston Pin, Piston Rings
            Ignition System
            Distributor Advance Characteristics
            Starter
            Engine Torque Specifications
        600 LOADER (WISCONSIN GAS)
            OPERATIONAL & PERFORMANCE
            ENGINE
            LOADER HYDRAULICS
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            COUNTERWEIGHT
            MACHINE WEIGHT (Less Bucket)
        610 LOADER (WISCONSIN GAS)
            OPERATIONAL & PERFORMANCE
            ENGINE
            LOADER HYDRAULICS
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            COUNTERWEIGHT
            MACHINE WEIGHT (Less Attachments)
    ENGINE SPECIFICATIONS (DEUTZ)
        ENGINE SPECIFICATIONS (Deutz F2L 411)
            Fuel System
            Lubrication System
            overn, Front Cover and Throttle
            Cylinder Head and Valves
            Cylinder, Piston and Connecting Rod
            Camshaft, Crankshaft, Bearings
            Torque Specifications
            Special Tools
        600D LOADER (DEUTZ DIESEL)
            OPERATIONAL & PERFORMANCE
            ENGINE
            LOADER HYDRAULICS
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
            COUNTERWEIGHT
            MACHINE WEIGHT (Less Bucket)
        611 LOADER (DEUTZ DIESEL)
            OPERATIONAL & PERFORMANCE
            ENGINE
            LOADER HYDRAULICS
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
            COUNTERWEIGHT
            MACHINE WEIGHT (Less Bucket)
        611D LOADER (BUREAU OF MINES APPROVED)
            OPERATIONAL & PERFORMANCE
            ENGINE
            LOADER HYDRAULICS
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
            COUNTERWEIGHT
            MACHINE WEIGHT (Less Attachments)
    ENGINE SPECIFICATIONS (PETTER)
        ENGINE SPECIFICATIONS (Petter)
            Fuel Specifications
            Engine Oil
            Specifications
            Lubrication System
            Cylinder Head
            Valve Mechanism
            Camshaft
            Crankshaft
            Crankshaft Regrinding Diameters
            Connecting Rod
            Piston
            Cylinder Block
            Torque Specifications
        600D LOADER (DEUTZ DIESEL)
            OPERATIONAL & PERFORMANCE
            ENGINE
            LOADER HYDRAULICS
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
            COUNTERWEIGHT
            MACHINE WEIGHT (Less Bucket)
    MOTOR SPECIFICATIONS, (ELECTRIC)
        600E LOADER (RELIANCE ELECTRIC)
            OPERATIONAL & PERFORMANCE
            MOTOR
            LOADER HYDRAULICS
            POWER TRAIN
            CAPACITIES
            TIRES
            COUNTERWEIGHT
            MACHINE WEIGHT (Less Attachment)
    TECHNICAL DATA
        LOADER TORQUE SPECIFICATIONS
            Hydraulic Fluid
            Special Tools
        DECIMAL AND MILLIMETER EQUIVALENTS
        U.S. TO METRIC CONVERSION
        STANDARD TORQUE SPECIFICATIONS FOR BOLTS
        
ALPHABETICAL INDEX

SERVICE BULLETINS
    019
    042
    
SERVICE MANUAL REVISIONS
    600-002
    600-003
    
    -