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


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 !!!! 

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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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