Bobcat 600 600D 610 611 Loader Service Manual 6556276 (6–12) - PDF DOWNLOAD

6 0 3 0 D 6 1 1

Service Manual

INCLUDES H SERIES

6 1 0

Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand Company and Bobcat Company or the products of either.

6556276 (6–12) 1 of 216

Printed in U.S.A.

© Melroe Company 1987

Dealer Copy -- Not for Resale

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Dealer Copy -- Not for Resale

MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

CORRECT

CORRECT

Lift Arm Support Device

Never service the Bobcat Skid-Steer Loader without instructions.

B-7469

B-1537

Use the correct procedure to lift or lower operator cab. Always use an approved lift arm support device to hold lift arms in raised position.

WRONG

WRONG

B-11799

B-15231

Cleaning and required daily.

maintenance

are

WRONG

B-15280

Have good vent ilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and g as can be produced.

Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a p art failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lif t arm support device. Replace it if damaged.

Never work on loader with lift arms up unless lift arms are held by a lift arm support device.

Never modify equipment or add attachments not approved b y Bobcat Company.

WRONG

WRONG

WRONG

B-6590

B-6580 B-16102

B-6589 B-16102 batteries produ ce

Stop, cool and clean engine of flammable materials before checking fluids.

Never service or adjust loader with the engine running un less instructed to do so in the manual.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes.

Never fill fuel tank with engine running, while smoking or when near open flame.

Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding.

Keep rear door closed except for service. Close and lat ch door before operating the loader.

Lead-acid flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be perform ed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer.

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B-10731a

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FOREWORD This manual provides instruction for proper routine servicing and adjustment of the Bobcat, and detailed overhaul instructions of the power train, loader hydraulic/hydrostatic system and general mainframe components.

Refer to the Owner ’s Manual for general operating instructions (Starting Procedure, Daily Check, Bucket Operation, Minor Maintenance, etc.).

A general inspection of the following items should be made whenever undergone service or repair:

GENERAL SERVICE

TROUBLE– SHOOTING

the machine has

1. Check hydraulic fluid level, engine oil level and fuel supply.

DRIVE SYSTEM

2. Inspect for any sign of fuel, oil or hydraulic fluid leaks.

3. Lubricate the machine.

HYDRAULIC SYSTEM

4. Check battery condition, electrolyte level and cables.

5. Inspect air cleaner system for damage or leaks. Check element and make replacement, if necessary.

6. Check alternator drive belt for condition and tension.

WISCONSIN ENGINE SERVICE

Dealer Copy -- Not for Resale

7. Check for loose drive chains by lifting the rear ofthe machine and turning the rear wheels by hand.

8. Check tires for wear and pressure.

DEUTZ ENGINE SERVICE

9. Check the Bob–Tach attachment for condition. Inspect the wedges for damage or wear.

10. Inspect safety items for condition (ROPS Guard, Seat Belt, Safety T reads, Lights, etc.).

11. Make a visual inspection for loose or broken parts or connections.

PETTER ENGINE SERVICE

12. Operate the loader, checking all functions.

Advise the owner if any of the above items are in need of repair.

CONTENTS

SPECIFICATIONS

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 ....

DEUTZ ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–1 ...

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–1 ....

GENERAL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 ....

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 ....

PETTER ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–1 ...

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–1 ....

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 ....

WISCONSIN ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ...

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ALPHABETICAL INDEX

600, 600D, 610, 611 Loader Service Manual

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600, 600D, 610, 611 Loader Service Manual

Paragraph Page Number Number CHANGING AND ADDING HYDRAULIC OIL . . . . . . . . . . . . .1–3 1–2 CRANKCASE AIR VENT (DEUTZ) . . . . . . . . . . . . . . . . . . . . . 1–15 .

1–7 CRANKCASE AIR VENT (WISCONSIN) . . . . . . . . . . . . . . . . .1–14 1–7 DISTRIBUTOR MAINTENANCE (WISCONSIN) . . . . . . . . . . . 1–22 1–10 ENGINE AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 ..

1–4 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .1–19 .

1–8 ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 ...

1–5 ENGINE OIL FILTER (DEUTZ) . . . . . . . . . . . . . . . . . . . . . . . . .1–12 .

1–6 ENGINE OIL FILTER (WISCONSIN) . . . . . . . . . . . . . . . . . . . . 1–11 .

1–6 FUEL ADJUSTMENT (PETTER) . . . . . . . . . . . . . . . . . . . . . . .1–18 .

1–8 FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 ...

1–7 FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16 ..

1–7 HEAVY DUTY AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . .1–8 .

1–4 HYDRAULIC FLUID FILTER CHANGE . . . . . . . . . . . . . . . . . . 1–5 .

1–3 IGNITION TIMING (WISCONSIN ENGINE) . . . . . . . . . . . . . . .1–21 1–9 LOADER LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 ..

1–2 OIL FILTER (PETTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–13 ..

1–6 OIL SPECIFICATIONS FOR ENGINES . . . . . . . . . . . . . . . . . .1–10 1–5 OIL TYPE AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 ..

1–4 REMOVING WATER FROM HYDRAULIC TANKS . . . . . . . . . 1–4 1–2 SPARK PLUG (WISCONSIN) . . . . . . . . . . . . . . . . . . . . . . . . . .1–23 .

1–10 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–1 ...

1–2 WATER SCRUBBER MUFFLER (600 DIESEL) . . . . . . . . . . . 1–20 1–8

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GENERAL SERVICE

Dealer Copy -- Not for Resale

GENERAL SERVICE

600, 600D, 610, 611 Loader Service Manual

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600, 600D, 610, 611 Loader Service Manual

ITEM

G,D,P,E G,D,P

All Loader Pivots Engine Air Cleaner (Dry Type)

D G,D,P G,D,P * G,D,P G,D,P E G,D,P,E G,D,P,E G,D,P G,D,P G G,D,P,E** D G,D,P G,D,P,E G,D,P G,D,P,E

Oil Bath Air Cleaner Engine Oil Engine Air Inlet Screen Cooling Fins & Shroud Starting Motor Cable Swivel Variable Sheaves Control Levers & Pedals Engine Oil Engine Oil Filter Distributor Cam (Wisconsin) Final Drive Chains Oil Bath Air Cleaner (Bureau of Mines) Engine Air Cleaner (Dry Type) Hydraulic Oil Filter Crankcase Breather Steering Clutches

D G G D D P G

Engine Valve Tappets Plugs & Points Generator (M–444) Engine Fuel Filter Engine Blower V–Belt Tension Engine Valve Tappets Engine Cylinder

G,D,P G,D,P,E G,D,P G

Engine Shroud Drive Belt & Sheaves Starting Motor Engine

D G,P,D,P P P P E G,D,P,E

Crankshaft Breather Hydraulic, Transmission Sump Engine Fuel Filter Oil Pump Strainer Engine Cylinders Motor Bearings Hydraulic, Transmission Sump

SERVICE REQUIRED Grease fittings (10) until excess shows.

Clean cup as necessary. Change cartridge only when indicator show red ring.

Check condition of oil Add to full mark. Do not overfill. Use correct oil for engine.

Check and clean as necessary.

Backflush with air as necessary.

Flush with air as necessary.

Put grease in fittings (2) until it shows.

Put grease in fittings (2); drive and driven sheave.

Put grease in fittings (7) until it shows.

Make replacement. Refer to Engine Manual.

Make replacement of element.

Put drop of oil in spring cap oil cup.

Make adjustment as necessary.

Clean and refill with engine oil.

Check operation of condition indicator.

Make replacement at 100 hours.

Inspect. Service as necessary.

Make adjustment when lever travel exceeds 3–4 inches from neutral in either direction (fully engaged).

Check clearance. Make adjustment if necessary.

Clean. Gap install new as necessary. Tighten spark plugs.

Add lubricant.

Clean or install new element.

Check. Make adjustment as necessary.

Check clearance. Make adjustment if necessary.

If over 90 PSI compression remove carbon from combustion chambers.

Remove to clean engine cooling fins.

Check for tension, alignment and wear.

Remove, clean and service.

Remove head. Clean carbon from combustion chambers.

Make adjustment of valves if necessary.

Clean copper mesh element.

Remove condensation. Check level. Add as necessary.

Clean or install new element.

Clean.

Remove carbon from combustion chambers.

Add lubricant. For interval, follow instructions plate on motor.

Make replacement of oil. Approximately 18 gallons are needed.

Dealer Copy -- Not for Resale

MODEL

HOURS 8–10 40–50 80–100 200 300 500 1000 2000

SERVICE SCHEDULE

Model Code: G, Gasoline & LP Gas; D, Deutz Diesel; P, Petter Diesel; E, Electric * On fertilizer, grain or other extremely dusty operations, clean more often as required. ** Adjust after first 50 hours of operation. Check daily if solid type tires are used.

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600, 600D, 610, 611 Loader Service Manual

GENERAL SERVICE 1–1 TIRES Tire air pressure on standard 7:00 x 15,6 ply should be 55 PSI (379 kPa).

Flotation tire air pressure should be 25 PSI (172 kPa). Air pressure must be the same in all tires for longer life.

Tires can be filled with calcium chloride for more load stability and traction. They must not be filled to more than 80% of capacity of tire.

NOTE: Flotation tires should not be filled with calcium chloride except in pulpwood operation.

A–01250

Tire rotation should be done when 1/8 inch (3,2 mm) dif ference is found in wear of tire (Fig 1–1).

Fig. 1–1 Tire Rotation

When putting new tire on loader, check that size is the same as other tires on loader.

1–2 LOADER LUBRICATION

1–3 CHANGING AND HYDRAULIC OIL

Dealer Copy -- Not for Resale

See Fig. 1–2 for lubricate fitting locations. Use a good lithium base grease. Check service schedule (Page 1–1) for correct time intervals.

ADDING

The loader holds 18 gallons of hydraulic oil which need not be changed unless loader is run under very dirty conditions for a long period of time.

Otherwise change oil every 1000 hours or if oil has become dirty or white in color.

Check oil level every 50 hours of operation, on a level surface. When low add approved oil and fill to the upper check plug (Fig. 1–3).

1–4 REMOVING W ATER HYDRAULIC TANKS

FROM

Water should be removed every 1000 hours of operation or more often if loader is operated in a climate where much water is present in the air.

PI–01033

VARIABLE SPEED DRIVEN SHEAVE ADJUSTMENT EXCEPT ON M–600 MODEL

PI–01027

Fig. 1–2 Loader Lubrication

To remove water from the reservoir: 1. Use tilt control to raise front wheels of the loader several inches off of the ground.

2. Allow the loader to stand for 3–4 hours.

3. Remove drain plug (Fig. 1–3) for water to run off .

Check Plugs

Drain Plug

B–01507

Fig. 1–3 Reservoir Check and Drain Plugs

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1–4a BOB–TACH FRAME Check Bob–Tach and weld areas as necessary (Fig. 1–3a).

1–5 HYDRAULIC FLUID FIL CHANGE

TER

See SERVICE SCHEDULE Page 1–1 for time interval.

1. Lower lift arms. Lift from of the loader 5–6 inches (127–152 mm) on 600 Electric and Petter diesel.

Lift rear of machine 5–6 inches on 600, 610 and Deutz diesel. This will prevent oil from running out when filter is removed.

A–02533

Fig. 1–3a Weld Areas

3. Remove seat and engine cover (600, 610 and Deutz 610).

Element

4. Remove element, seals and spring from housing (Fig. 1–4).

Dealer Copy -- Not for Resale

2. Remove floor panels and disconnect linkage (600 Electric and Petter diesel).

Spring

5. Remove seal from center shaft (Fig. 1–4, Item 1).

6. Clean parts in a cleaning fluid and dry.

7. Assemble new filter (Fig. 1–4).

Seals

2 1

8. Check housing seal (Fig. 1–4, Item 2).

9. Install filter assembly to loader and tighten nut to 12 ft.–lbs. (83 kPa) (Fig. 1–5).

C–01244

Fig. 1–4 Hydraulic Fluid Filter Assembly

10. Lower the loader and run engine at idle until hydraulics work smoothly.

Fill Port

11. Check for leaks and check level of fluid. It should need 2 quarts (1.9 ltr.) for filter element. Fill to the upper check plug (Fig. 1–6).

Check Ports C–01785

Fig. 1–5 Installing Filter Assembly 11 of 216 Revised February 80

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Drain Port PI–01019

Fig. 1–6 Hydraulic fluid Level Check 600, 600D, 610, 611 Loader Service Manual

1–6 ENGINE AIR CLEANER 1. See SERVICE SCHEDULE (Page 1–1) for intervals.

2. Clean all foreign material from outside of housing.

3. Remove old element (Fig. 1–7).

4. Install new element (Fig. 1–7).

5. Set indicator ring back to normal (Fig. 1–8).

6. Inspect air cleaner for leaks: a. Dust cap holder b. Filter gasket c. Dust cap

C–01024

Fig. 1–7 Air Cleaner Assembly

d. Dust cap sealing edge Reset Button

Dealer Copy -- Not for Resale

e. Filter leaks f. Hose and connections. g. Check system by removing dust cover and hold hand over inlet with engine running atidle to 1/4 throttle. Engine should stop (Fig. 1–11). Reset indicator and install dust cover.

1–7 OIL TYPE AIR CLEANER 1. Stop loader and let stand for one hour.

2. Remove bottom cup and clean.

3. Fill cup with oil to correct level (Fig. 1–9).

A–01600

Fig. 1–8 Condition Indicator

Cup Fig. 1–9 Oil Bath Air Cleaner

4. Install cup.

1–8 HEAVY DUTY AIR CLEANER 1. An indicator located on front of air cleaner indicates condition of filter (Fig. 1–10).

2. When red ring is in window , remove element and install new element (Fig. 1–10).

NOTE: Do not clean or install old element.

3. Inspect hoses and connection for leaks.

Indicator

4. Inspect and clean vanes on air cleaner (Fig. 1–10).

C–01088

Fig. 1–10 Heavy Duty Air Cleaner 12 of 216 80 Revised February

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A–01600

Fig. 1–11 Checking System 600, 600D, 610, 611 Loader Service Manual

1–9 ENGINE OIL 1. Check SERVICE SCHEDULE on page 1–1 for time interval.

2. Empty oil when engine is warmed up.

3. Capacity of oil for engine follows: Wisconsin=7 pints (3,3 L)+1 pint (,5 L) when filter is changed.

Deutz=4–1/2 quarts (4,2 L) with filter.

Petter=5–1/2 quarts (5,1 L) with filter.

1–10 OIL SPECIFICATIONS FOR ENGINES Replace the engine oil and filter every 50 hours of loader operation.

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE)

–23 –18

–13

–7

–1

+4

+10 +15

+21

+27 +32 +38

+43

+49

+54 +60

+70

+80 +90 +100 +110 +120 +130 +140

SAE 10W–30

SAE 15W–40 SAE 5W–30 SAE 30W

SAE 20W–20

SAE 10W

⎧°–30 –20

–10

0

+10

+20 +30

+40 +50 +60

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (GASOLINE: USE API CLASSIFICATION SE) (DIESEL: USE API CLASSIFICATION CD)

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C°–34 –29

600, 600D, 610, 611 Loader Service Manual

1–11 ENGINE OIL FILTER (Wisconsin) Check SERVICE SCHEDULE Page 1–1 for time interval.

1. Remove filter element (Fig. 1–12).

2. Install new filter and hand tighten (Fig. 1–13).

3. Start engine and check for leaks.

4. Run engine at full throttle for 1 minute then stop engine.

5. Tighten filter by hand.

1–12 ENGINE OIL FILTER (Duetz Diesel – Fig. 1–13) Change the filter element at every engine oil change. o T change the filter, use this procedure: 1. Remove and discard the oil filter cartridge.

B–01832

Fig. 1–12 Remove Engine Oil Filter 2. Install a new filter cartridge, turn it on hand tight.

Dealer Copy -- Not for Resale

3. Start the engine and run it at idle for five minutes while checking for oil leaks at the filter.

4. Run the engine at full throttle (2400 RPM) for at least one minute, then stop engine.

5. Tighten the cartridge again (hand tight).

OIL FILTER (Petter) See SERVICE SCHEDULE Page 1–1 for time interval.

1. Remove filter cover (Fig. 1–14).

2. Remove oil filter element.

3. Clean filter housing anD remove dirt and oil.

4. Install new element and tighten cover to 10 ft.–lbs. (13,55 Nm).

NOTE: After installing oil filter on engines, run engine and check for leaks. Stop engine and check oil level.

WARNING

Fig. 1–13 Install Engine Oil Filter (Deutz)

Filter

Filter Cover

Cold weather starting (below 32°F.) with heavier than 10W engine oil can stretch the filter cartridge causing a leak.

Tighten the filter cartridge after every few cold starts to be sure it stays tight.

W–2265–0997

14 of 216 80 Revised February

Fig. 1–14 Remove Filter cover (Petter) –1–6–

600, 600D, 610, 611 Loader Service Manual

1–14 CRANKCASE AIR VENT (Wisconsin) 610,611ServiceManual#6556276–Contents&GeneralServiceSectionPages1–7

See SERVICE SCHEDULE Page 1–1 for time interval. Inspect fittings and hoses for leaks (Fig. 1–15).

1–15 CRANKCASE AIR VENT (Deutz) See SERVICE SCHEDULE Page 1–1 for time interval. The vent housing contains a copper element as a filter.

1. Remove bolts that hold crankcase vent housing in place (Fig. 1–16).

2. Remove housing and vent tube assembly from engine (Fig. 1–17).

Lay it face up and install clean copper element.

C–01569

Fig. 1–15 Crankcase Air Vent (Wisconsin)

3. Install vent tube on engine. Check that housing is correct on engine.

Seal it using an industrial cement before tightening bolt.

1–16 FUEL SPECIFICATIONS Wisconsin gasoline.

engine uses

A–01601

regular

Fig. 1–16 Crankcase Breather (Deutz)

Deutz engine uses a number 2 diesel fuel for temperatures above 30°F. Petter engine uses number 2 diesel fuel.

Fig. 1–17 Deutz Breather W/Element

Element

1–17 FUEL FILTER L.P. Gas: (WIsconsin)

A filter with an ignition switch actuated shut–of f lock is located between the inlet hose and vaporizer. This must be serviced regularly. Remove the old element and install new element when servicing (Fig. 1–18).

Deutz:

Remove fuel filter and install new filter every 200 hours (Fig. 1–19). Air removal from fuel lines is necessary after filter service.

Petter:

Remove fuel filter and install new filter every 1000 hours (Fig. 1–20). Air removal from fuel line is necessary after filter service.

Wisconsin: (Deutz)

Remove in–line filter every 200 hours.

Check condition by blowing through element, in same direction as arrow.

Make replacement of dirty element.

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B–01171

Fig. 1–18 LP Gas Fuel Filter

A–01592

Fig. 1–19 Deutz Fuel Filter –1–7–

Dealer Copy -- Not for Resale

NOTE: Remove vent tube from engine every 500 hours and wash element in cleaning solvent.

A–01591

Fig. 1–20 Petter Fuel Filter 600, 600D, 610, 611 Loader Service Manual

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610 Loader Service Manual

1–17a EXCESS FUEL LEVER ADJUSTMENT (Deutz Engine) 610,611ServiceManual#6556276–Contents&GeneralServiceSectionPage7a

Engine does not start because excess fuel lever does not operate correctly. The excess fuel button must be pushed fully down, when thethrottle lever is pulled all the way backward while stopping the engine, this is done through movement of the excess fuel lever (Fig. 1–20a).

Check the operation of the lever by pulling the throttle lever fully backward. While the throttle is held in this position check to see if the excess fuel buttonis pushed down by the adjustment bolt (Fig. 1–20b, Item 1). Make an adjustmentof the bolt if necessary to fully push the excess fuel button down. Install a longer bolt if no more adjustment can be made.

Fig. 1–20a Excess Fuel Button

After adjustment is made check the operation by pulling throttle lever all the way backward as in stopping the engine. Then move throttle forward to the 1/2throttle position. Check the excess fuel button. It must continue to be in the down position for starting the engine. If the button is not down, more adjustment of the excess fuel lever is necessary.

1 2

1–17b FUEL PUMP (Wisconsin)

3

If fuel pump pressure is too high the engine will get too much fuel. Check fuel pump pressure by installing a tee in the fuel line between fuel pump and carburetorand connecting a gauge to the tee. Run the engine at full RPM. Correct pressure is 2–3 PSI. If pressure is too high, install newspring from fuel pump repair kit. (See Parts Manual.)

NOTE: Too low pressure will cause vaporlock.

Dealer Copy -- Not for Resale

If necessary make additional adjustment by bending the cam plate end of the excess fuel lever (Fig. 1–20a, Item 2) down. (Do not bend the plate so much as to prevent full movement of the fuel rack lever (Fig. 1–20a, Item 3).

A–02468

A–02467

Fig.

1–20b

Adjustment

Excess Fuel Lever

Make adjustment of float level to 1–5/32 inch (28,58 mm).

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600, 600D, 610, 611 Loader Service Manual

1–18 FUEL ADJUSTMENT (Petter)

RIGHT SIDE OF MACHINE

Inspection Plate

1. Stop engine.

8–3/8’’ 2. Remove cover plug (Fig–1–21).

NOTE: When loader is not equipped with a hole in loader side wall at fuel adjustment screw location see Fig. 1–21 for hole drilling instructions.

The hole will make fuel adjusting easier.

3. Put a screw driver into hole (Fig.1–21). Turn in to reduce fuel supply. turn out to increase fuel supply.

Drill 1’’ Dia. Hole Where Areas Cross.

12–1/4’’

Drain Plug Fig. 1–21 Locating Fuel Adjustment Hole (Petter)

4. Install plug. Start engine and check its operation. Set for a maximum power and minimum smoke.

1. All air cooled engines must have proper air circulation to cool well.

2. Keep blower fan and screen clear of foreign material and housing free of leaks and dents.

A–01071

Fig. 1–22 Deutz Cooling Fan

Cooling Fins

A–02496

Fig. 1–23 Clean Cooling Fins (Petter)

3. Remove housing and clean cooling fins when need (Fig. 1–22, 1–23, & 1–24).

WARNING

Never run the engine with holes in cooling housing or with any part of cooling housing removed.

W–2266–0997

1–20 WATER SCRUBBER MUFFLER (600 Diesel) The following applies to United States Bureau of Mines approved model 600 equipped with an exhaust gas conditioner (Water Scrubber Muffler).

1. Exhaust pipe and connections from engine to exhaust gas conditioner must be kept tight and free from leaks at all times.

2. Empty scrubber at bottom outlet with engine running, after each shift (10 hours).

B–02417

Fig. 1–24 Cleaning Cooling Fins (Wisc.)

Level Check Valve

3. Fill with clean water until water level reaches level check valve located on front of scrubber (Fig.1–25).

4. Flush scrubber twice weekly by filling it with water while engine is running at high idle. This will agitate water and any excess will be blown out with exhaust gas.

C–01856

Fig. 1–25 Check Level Scrubber Muffler 18 of 216

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1–19 ENGINE COOLING SYSTEM

5. Check exhaust, check valve (located between engine and exhaust gas conditioner) (Fig. 1–26). Check each day to make sure it will open when suction is applied to exhaust pipe. The check valve is intended to keep water from entering engine in event engine turns over backwards (opposite of normal rotation).

Check Valve

1–21 IGNITION TIMING (Wisconsin Engine) Find the timing notch on air screen of flywheel and make sure it is positioned in line with the large DC letters on flywheel, behind screen (Fig. 1–27).

NOTE: Ignition point gap must be correct before timing engine.

To check timing:

C–01856

Fig. 1–26 Exhaust Check Valve

1. Connect timing light to number one spark plug.

2. Start engine and run at over 1800 RPM.

a.

VF4D engine (Model 600 Bobcat) is timed at 27° before dead center. Check to see that timing notch is inline with the timing mark on flywheel housing (Fig. 1–27, Item 1).

b.

VH4D engine (Model 610 Bobcat) is timed at 23 ° before dead center. Check to see that timing notch is inline with the lowe r half of the timing hole in flywheel housing (Fig. 1–27, Item 2).

4. To adjust timing, loosen the distributor clamp screw and turn the distributor body until timing is correct (Fig. 1–29).

VH4D

23° Marked Air Vane On Flywheel

VF4D

Running Spark Advance timing Mark For Checking With Neon Light

PI–01437

2

1

Dealer Copy -- Not for Resale

3. Point timing light so that it will show the notch on flywheel screen (Fig.1–28).

Centerline Mark Of No. 1 Cylinder

5. When timing is correct, tighten the distributor clamp screw.

B–02629

WARNING

B–02630

Fig. 1–27 Ignition Timing

Engine must be running at over 1800 RPM when making timing adjustment. W rong engine timing can damage engine.

W–2267–0997

C–01799

Fig. 1–28 Check Notch W/ Timing Light 19 of 216 (Revised 1–78)

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600, 600D, 610, 611 Loaders Service Manual

1–22 DISTRIBUTOR MAINTENANCE (Wisconsin) 1. Turn the engine over by hand until the breaker arm block is on a a high point of cam (Fig. 1–29).

2. Loosen the stationary contact lock nut and turn screw in or out until contact gap is correct (Fig. 1–29).

3. Tighten the lock nut and check gap (Fig. 1–29).

1–23 SPARK PLUG (Wisconsin) A–01836

Fig. 1–29 Distributor Maintenance

Dealer Copy -- Not for Resale

The spark plug gap should be .030 inch.

Plug should be kept clean both inside and out (Fig. 1–30). When insulation is broken, install a new plug of correct heat range. Tighten the spark plug to 25–30 ft.–lbs. (34–40 Nm) torque.

A–01825

Fig. 1–30 Spark Plug Gap

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1–24 ELECTRICAL SYSTEMS CHECKING RECTIFIER

REGULATOR

AND 10–30 Ohms

NOTE: Read this completely before attempting any checks.

Ground B–01172

Fig. 1–31 Wiring Diagram

1. Disconnect the connectors by squeezing the outer ends of the receptacles and pulling apart.

Fig. 1–32 Rectifier Check #1

Any reading indicates a short circuit

2. Remove the modules from their position behind the distributor.

PI–01358

10–45 Ohms

3. Install the modules on the shroud at the rear of the engine. Install the rectifier slightly higher and to the left of the regulator module.

NOTE: The rectifier and regulator modules are grounded to the engine frame. You will need to remove paint from the shroud to get a metal to metal contact between the base of the modules and the shroud. Do not install the modules anywhere other than on the engine.

Ground

Ground

PI–01358

Fig. 1–33 Rectifier Check #2

PI–01358

Fig. 1–34 Rectifier Check #3

Any reading indicates a short circuit

Any reading indicates a short circuit

Ground

Ground

4. Use a jumper harness (Fig. 1–31, Item 1) to connect the stator leads to the rectifier and regulator modules [A].

The keyed connectors prevent incorrect wiring.

Examine the leads for broken wires, or loose connections. If none are found, disconnect the battery and disconnect the rectifier and regulator modules from the jumper harness. Make sure the bases of the modules are making good contact with the engine shroud.

PI–01358

Fig. 1–35 Rectifier Check #4

NOTE: If your ohmmeter does not give you the readings shown in Figures 1–32 thru 1–41, reverse the leads going into your meter. If the readings still differ from the readings listed, replace the part tested.

21 of 216 (Added 1–78)

PI–01358

Fig. 1–36 Regulator Check #1

Any reading indicates a short circuit

Use a ohmmeter to check for defects in the rectifier and regulator. All the checks can be completed without removing anything from the machine. If a meter connection is shown going to ground, it means engine ground. Be sure you have a good ground connection.

Dealer Copy -- Not for Resale

VF4D Wisconsin engines have the recifier and regulator modules mounted to the shroud at the rear of the engine.

On some engines the rectifier and regulator modules are behind the distributor. They are hard to check the service. You may want to move the modules out onto the shroud. To do this:

Any reading indicates a short circuit

Ground PI–01358

Fig. 1–37 Regulator Check #2 –1–11–

PI–01358

Fig. 1–38 Regulator Check #3 600, 600D, 610, 611 Loaders Service Manual

STATOR CHECKS Use a test light (or continuity tester) to check for shorts from the stator leads to ground. The test light will give indication of any shorts by illuminating the bulb. If the bulb indicating there is a short, the stator will need show that replacement.

If the bulb does not illuminate when checking any of the stator leads to ground, check to make sure there is continuous circuit, go onto the voltage check. Use a voltmeter to check the stator. Run the engine at full RPM when taking these readings.

NOTE: The voltmeter readings can be different from the ones shown in Figures 1–42 thru 1–46. Use the reading given only as a guide.

Any reading indicates a short circuit

Any reading indicates a short circuit

Ground PI–01358

Fig. 1–39 Regulator Check #4

PI–01358

Fig. 1–40 Regulator Check #5

125–450 Ohms

50 Volts A.C.

NOTE: If the engine is not run at full RPM the readings can be different.

If all checks are made and all readings are acceptable, but the battery doesn’t charge, there is probably a bad connection in the wiring harness or the battery terminal.

Ground PI–01358

NOTE: The blue wire, as referred to in these tests, is the wire next to the red wire. It is blue coming off the stator, but can be any color next to the connector.

PI–01359

Fig. 1–42 Stator Check #1

Fig. 1–41 Regulator Check #6

20 Volts A.C.

20 Volts A.C.

PI–01359

Fig. 1–43 Stator Check #2

PI–01359

Fig. 1–44 Stator Check #3

140 Volts A.C.

Regulator Disconnected 20 Volts D.C.

Ground PI–01359

Fig. 1–45 Stator Check #4 22 of 216 (Added 1–78)

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PI–01359

Fig. 1–46 Stator Check #5 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

If the stator is bad the readings will be a lot different from the readings shown.

They will be lower readings.

Starter Switch

LEGEND

Ammeter Gauge

Blk = Black Bl = Blue Brn = Brown Gr = Green Or = Orange Pi – Pink Pu = Purple Rd = Red Wh = White Yel = Yellow J = Jumper + = Positive – = Negative = Ground

Dealer Copy -- Not for Resale

Oil Pressure Indicator

Fuse

Voltage Regulator

Alternator Coil

Oil Pressure Switch Hour Meter Switch

Starter

B–01176 B–01179 C–01376 23 of 216

(Added 1–78)

–1–13–

600, 600D, 610, 611 Loaders Service Manual

ALTERNATOR CHECK The following test can be made with the alternator in the machine. Disconnectall wires from the alternator except the ground wire. Connect a jumper wire from the field connector to the battery connector. Also connect a voltmeter and ammeter into the circuit as shown in the wiring diagram (Fig. 1–48).

JUMPER WIRE AMMETER GRD.

BAT.

BATTERY

VOLTMETER

If the alternator charging rate is within limits, but the battery is still undercharged or overcharged, the following voltage regulator tests should be made.

DELCOTRON

NOTE: An overcharged battery condition is usually indicated by the battery using an excessive amount of water, or by being hot on top.

Fig. 1–48 Alternator Check

PI–02269

REGULATOR CHECK #1 Use a 12 volt test light. Fasten onewire of test light to #3 connector on the regulator and fasten the other end to ground. The test light must come on. If the light does not come on, there is an open circuit between the battery and #3 connector.

IGNITION ‘‘ON’’ REGULATOR CHECK #2

BLACK

REGULATOR

Connect the voltmeter red lead (positive) to the #2 terminal on the regulator. Connect the voltmeter black lead (ground) to the base of the regulator (Fig. 1–50). The ignition switch must be turned on. The voltmeter must show 12 to 14 volts. If the voltmeter shows a very low or zero reading the circuit is open between #2 terminal on the regulator and the ignition switch and the wiring must be replaced.

RED VOLTMETER

PI–02270

Fig. 1–49 Regulator Check #1 24 of 216 (Added 1–78)

–1–14–

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

With the engine at full RPM and a carbon pile rheostat (equivalent to 25 amp. current draw) connected across the battery, the alternator must give an output of at least 14 amps (maximum rated output is 22 amps). If the alternator does not give at least 14 amps, it is defective and should be serviced at an authorized Delco–Remy Service Center.

LOAD

A 12 volt test light can also be used.

Connect one wire of the test light to #2 terminal on the regulator and connect the other wire to the regulator base (ground). With the ignition switch on, the test light must come on. If it does not, the circuit is open between #2 terminal and the ignition switch. A noise will be head whenever the #2 wire leading to the regulator is disconnected or reconnected. The noise is caused from the contact points opening and closing.

IGNITION ‘‘ON’’ BLACK

REGULATOR REGULATOR CHECK #3 Disconnect the wire leading to the F (field) terminal on the regulator .

Connect the read wire (positive) of a voltmeter to the F (field) connector on the regulator. Connect the black wire (ground) to the regulator base (Fig. 1–51). The ignition switch must be turned on. A zero reading is an indication that the contact closing voltage setting is incorrect and the regulator unit must be adjusted or replaced.

VOLTMETER

Dealer Copy -- Not for Resale

A 12 volt test light can also be used.

Connect one wire to the F terminal on the regulator. Connect the other wire to the regulator base (ground).

The ignition switch must be on. The test light must come on if the light does not come on, adjust the voltage setting or replace the regulator.

RED

PI–02271

Fig. 1–50 Regulator Check #2

If the battery is undercharged and has low voltage, the upper contacts in the voltage regulator are closing too soon.

If the battery is overcharged and losing water because of too high a charging rate, the upper contacts in the voltage regulator are not closing soon enough.

IGNITION ‘‘ON’’ BLACK

REGULATOR

If either condition exists, have the regulator adjusted to specifications at an authorized Delco–Remy Service Center.

RED VOLTMETER

PI–02272

Fig. 1–51 Regulator Check #3 25 of 216 (Added 1–78)

–1–15–

600, 600D, 610, 611 Loaders Service Manual

Oil Pressure Indicator Ywl

LEGEND J4

J1

J3

Starter Switch

Pu

J2

Blk

J4

J3 Or

Blk = Black Bl = Blue Brn = Brown Gr = Green Or = Orange Pi – Pink Pu = Purple Rd = Red Wh = White Yel = Yellow J = Jumper + = Positive – = Negative = Ground

Rd

Ammeter Gauge

Pre–Heater Switch

J2

Oil Pressure Switch

J1

Glow Plug Indicator

Dealer Copy -- Not for Resale

Hour Meter Gauge

Fuse

Oil Pressure Switch

Hour Meter Switch Voltage Regulator

Generator Pre–Heater Solenoid Starter Fig. 1–52 Electrical Circuitry (Deutz W/Generator) 26 of 216 (Added 1–78)

–1–16–

B–01175 B–01181 C–01376

600, 600D, 610, 611 Loader Service Manual

Oil Pressure Indicator J1

Brn

LEGEND BW

Starter Switch

Wh

J2

Or

J3

Blk

Rd

PW 1 J3 Pu

Blk = Black Bl = Blue Brn = Brown Gr = Green Or = Orange Pi – Pink Pu = Purple Rd = Red Wh = White Yel = Yellow J = Jumper + = Positive – = Negative = Ground

Ammeter Gauge

Pre–Heater Switch

J2

Oil Pressure Switch

Glow Plug Indicator

Dealer Copy -- Not for Resale

Hour Meter Gauge

Fuse

Oil Pressure Switch

Resistor

Hour Meter Switch

Alternator Pre–Heater Solenoid Voltage Regulator Fig. 1–53 Electrical Circuitry (Deutz W/Delco Alternators) 27 of 216 (Added 1–78)

–1–17–

Starter

B–01175 C–01455 C–01376

600, 600D, 610, 611 Loaders Service Manual

Oil Pressure Indicator

LEGEND

J2 Gr

J2

Blk J1

Starter Switch

Pu

Or

Blk = Black Bl = Blue Brn = Brown Gr = Green Or = Orange Pi – Pink Pu = Purple Rd = Red Wh = White Yel = Yellow J = Jumper + = Positive – = Negative = Ground

Rd

Yel Pi

Ammeter Gauge Pre–Heater Switch

J1 J1

J3

J3

Oil Pressure Indicator

Dealer Copy -- Not for Resale

Hour Meter Gauge

Fuse Glow Plug Indicator

Oil Pressure Switch

Hour Meter Switch

Alternator

Pre–Heater Solenoid

Starter B–01176 B–01247 C–01376

Fig. 1–54 Electrical Circuitry (Deutz W/Lucas Alternators) 28 of 216 (Added 1–78)

–1–18–

600, 600D, 610, 611 Loader Service Manual

Starter Switch Pi

Circuit Breaker

LEGEND Blk = Black Bl = Blue Brn = Brown Gr = Green Or = Orange Pi – Pink Pu = Purple Rd = Red Wh = White Yel = Yellow J = Jumper + = Positive – = Negative = Ground

J1

Grn J2

Blk Pu

J1 J2

Oil Pressure Indicator

Rd

Ammeter Gauge

Or

Dealer Copy -- Not for Resale

Hour Meter Gauge

Voltage Regulator

Engine (overheat) Shut–Off Switch

Alternator Oil Pressure Switch Starter

B–01176 B–01180 C–01376

Fig. 1–55 Electrical Circuitry (Petter W/Delco Alternators) 29 of 216 (Added 1–78)

–1–19–

600, 600D, 610, 611 Loaders Service Manual

Oil Pressure Indicator

Starter Switch

610,611ServiceManual#6556276–Contents&GeneralServiceSectionPages8–20

Or

LEGEND Blk

J1

Blk = Black Bl = Blue Brn = Brown Gr = Green Or = Orange Pi – Pink Pu = Purple Rd = Red Wh = White Yel = Yellow J = Jumper + = Positive – = Negative = Ground

Pi J1 B1

Wh

Ammeter Gauge

Rd J1

Oil Pressure Indicator

Dealer Copy -- Not for Resale

Hour Meter Gauge

Fuse

Oil Pressure Switch

Starter Fig. 1–56 Electrical Circuitry (Petter W/Lucas Alternators) 30 of 216 (Added 1–78)

Alternator

B–01176 C–01401 C–01376

–1–20–

600, 600D, 610, 611 Loader Service Manual

TROUBLESHOOTING Page Number 2–1 2–11 2–5

TROUBLE– SHOOTING

Dealer Copy -- Not for Resale

Paragraph Number TROUBLESHOOTING THE DRIVE SYSTEM . . . . . . . . . . . . .2–1 TROUBLESHOOTING THE ENGINE . . . . . . . . . . . . . . . . . . . 2–3 .

TROUBLESHOOTING THE HYDRAULIC SYSTEM . . . . . . . 2–2

31 of 216

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Dealer Copy -- Not for Resale 32 of 216

–2–0–

600, 600D, 610, 611 Loader Service Manual

2–1 TROUBLESHOOTING THE DRIVE SYSTEM

Early clutch thrust bearingsfailure.

Early clutch lining failure and wear.

Oil leakage of upper jackshaft bearings.

Ref.

Clutch shafts out of adjustment.

Make clutch adjustment.

Using wrong oil.

Put in correct oil.

Actuated thread hitting sidewall.

Correct clutch adjustment.

Bearings are not correctly located in clutch plate hubs.

Bearings should be even witheach end of hub.

Large hex nut hangs up on side cover.

Change position of nut.

Clutches over tightened, no neutralon control levers.

Correct clutch adjustment.

Force needed to release clutches. No full thread contact between actuating threads and actuating nuts. Threads and nuts are worn unevenly.

Install new actuating threads and nuts.

Rough races on clutch plates.

Install new bearings and races on both clutches.

Operator putting more force than necessary on levers.

Use less force on levers.

Wrong amount of counterweight.

Use correct counterweight.

Alignment nut not making correct alignment.

Free alignment nut.

Rough clutch faces.

Install clutch face and lining.

Clutch adjustment not correct.

Install clutch lining and clutch adjustment.

Clutch lubrication tubelines have restriction.

Inspect tubelines for restriction.

Clutch lining has been forced shoulder of inside clutch plate.

More than normal primary drive chain wear.

CORRECTION

on

make

Install clutch lining and check so it fits loosely on shoulder of inside clutch plate.

Upper jackshaft sprocket not in alignment with outer clutch sprocket.

Make adjustment for alignment.

Chain is over tightened.

Make chain adjustment.

Bearing in backward.

Install bearing correctly.

Bad shaft.

Inspect shaft and install new shaft.

Bad seal in bearing.

Install new bearing and seal.

Bad gasket for bearing housing.

Tighten housing holding bolts.

Dealer Copy -- Not for Resale

Clutch will not drive or engage correctly.

CAUSE

SEE SECTION 3

PROBLEM

correct

Install new gasket.

Oil leakage by clutch shaft caps.

Cap loose.

Tighten cap.

O–ring seal installed wrong.

Install new O–ring seal.

Bad O–ring seal.

33 of 216

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600, 600D, 610, 611 Loader Service Manual

2–1 TROUBLESHOOTING THE DRIVE SYSTEM (Cont’d) PROBLEM Roto–Swivel Leak.

Variable speed belt moves higher than required, then goes below its required position.

CAUSE

CORRECTION

O–ring or seal worn.

Install new O–ring or seal.

Pressure higher than necessary.

Make pressure adjustment.

Worn O–rings in push rod of variable speed valve.

Install new O–rings.

Leaking O–rings in variable drive.

Make pressure adjustment.

speed

Ref.

Direction control lever side play.

Loud noise in drive system.

Side panel is difficult to install.

Smooth and install seal kit.

Clutch thrust bearing.

Install new bearing.

Threads are bad on actuator nut.

Install new actuator nut.

Splines are worn on direction control lever or linkage shaft.

Install new lever and shaft.

Bolt is missing from direction control lever.

Install bolt.

Splines are worn on direction control lever or linkage shaft.

Tighten the bolt.

Holding nut is worn.

Install new nut.

Direction control lever linkage is loose Tighten the bolt. on lever.

Spring washers are not in place on actuating bar.

Put spring washers in correct place.

Actuating bar is bent.

Straighten bar or install new bar.

Actuating nut hits bottom against side wall.

Correct clutch adjustments.

Primary chain is over tightened.

Loosen and make adjustment.

Chain is out of alignment.

Make correct alignment.

Upper jackshaft bearings are bad.

Install new bearings.

Secondary chain is out of adjustment.

Make correct adjustments.

Lower jackshaft sprocket is loose.

Tighten sprocket.

Self–alignment nut is not turned correctly.

Turn self–alignment nut so a flat is on top.

Secondary tightened.

Correct adjustment on chain.

drive chain is over

Primary drive chain is over tightened.

34 of 216

–2–2–

Correct adjustment on chain.

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

Increase in direction control lever movement in one direction.

Stationary half sheave rough inside.

SEE SECTION 3

Install new O–rings.

2–1 TROUBLESHOOTING THE DRIVE SYSTEM (Cont’d) CORRECTION Turn spring so it will clear fitting.

Lubricant fitting on variable speed driven sheave is breaking off.

Spring hits the fitting compression.

Loss of power with drive belt.

Belt hits bottom on drive sheave.

Move lever forward to move belt outward when placing variable speed in low position.

Spring load jackshaft sheave not in adjustment.

Make sheave adjustment.

Grease on faces of drive and driven sheaves.

Clean sheaves.

Belt is worn.

Install new belt.

Alignment of driven sheave.

Make correct alignment.

Spring loaded sheave adjustment too tight.

Make adjustment of sheave.

Moving half of driven sheave not sliding free of shaft.

Clean sheave and shaft and lubricate.

Three sliding bolts are bearings on driven sheave are worn.

Install new parts.

Engine has come loose causing alignment to be off.

Correct alignment and inspect for wear.

Bore of fixed half of driven sheave is worn.

Install sheave and jackshaft.

Too high lift pressure.

Correct pressure.

Chains are tight and there is free play in wheels.

Sprocket holding nuts are loose.

Tighten and lock the nuts.

Worn axle splines or multiple sprockets.

Install new axle or sprockets.

Breaking of axle sprocket.

Using wrong sprockets.

Install correct sprockets.

Using wrong type chain.

Install correct chain.

Using wrong type chain connector.

Install correct chain connector.

Chain hitting other parts.

Inspect chain for clearance and correct.

Out of round sprocket.

Install new sprocket.

Bushing missing on axle to hold sprocket in place.

Install bushing.

Filling bucket with front wheels off the ground.

Keep all four wheels on ground.

Wrong type chain.

Install correct chain.

Wrong type chain connector.

Install correct chain connector.

Wrong balanced weight.

Use correct balanced weight.

Using solid tires.

Reduce speed with solid tires.

Breaking of drive belt.

Breaking of axle.

35 of 216

–2–3–

under

Ref.

Dealer Copy -- Not for Resale

CAUSE

SEE SECTION 3

PROBLEM

600, 600D, 610, 611 Loader Service Manual

2–1 TROUBLESHOOTING THE DRIVE SYSTEM (Cont’d) CORRECTION

Chains are not tight enough.

Tighten chains.

Worn chains and sprocket.

Install new chain and sprocket.

Using wrong axle sprockets.

Install correct sprockets.

Operating with different diameter tires on same side of loader.

Install tires with same diameter.

Using solid type tires.

Install air filled tires.

Loose items in tank.

Remove.

Using wrong chain.

Install correct chain.

Using more counterweight than is needed.

Use correct amount of counterweight.

Ref.

Dealer Copy -- Not for Resale

Breaking drive chains.

CAUSE

SEE SECTION 3

PROBLEM

36 of 216

–2–4–

600, 600D, 610, 611 Loader Service Manual

2–2 TROUBLESHOOTING THE HYDRAULIC SYSTEM PROBLEM Hydraulic system failure.

Rough hydraulic movement.

CAUSE

CORRECTION

Oil level.

Check hydraulic oil level and fill to top check plug.

The hydraulic pump is not moving.

Check pump coupling.

Master release valve is held open.

Clean master release valve.

Clutch manifold release valve is held open.

Remove valve and clean it.

Air in hydraulic system.

Vent air from tubelines and cylinders by pushing cylinders as far as they will go in both directions, push pedal for about 10 seconds each way.

Ref.

Remove the valve and clean it.

Dirty hydraulic oil filter is causing low flow and high vacuum.

Change the hydraulic oil filter whenever the indicator needle on the gauge is in red zone.

The large nut on end of filtercontainer is not tightened.

Tighten large nut to only 12 foot pounds (1.7 m/kgf).

Air is entering the hydraulic pump beyond the shaft seal.

Install a new seal

Lift arm raises slowly at full engine Lifting more than loaders rated RPM. capacity.

Operate loader within rated capacity.

There is an oil leak beyond piston seals in one or both lift cylinders.

Lift control linkage is out adjustment.

Dealer Copy -- Not for Resale

Foreign material in clutch manifold release valve holds valve open so air is pulled into the hydraulic pump through the clutch shafts.

SEE SECTION 4

A leak between reservoir and Check all fittings and fasteners for hydraulic pump causes air to enter the tightness. Check that fittings on pump. back of the vacuum gauge (hydraulic oil filter condition indicator) on right instrument panel are tight.

Check the piston seals. of

Leaking spool inside lift cylinder.

Make adjustment of linkage.

When spool is not centered in the valve with the pedal in neutral position, make linkage adjustment.

When spool or valve housing is broken or marked, replace the valve.

37 of 216

Hydraulic pump is worn and not delivering its rated volume of oil.

Check condition of the pump and repair or install new pump.

Fluid may have been used to fill the hydraulic system of a new attachment.

Add hydraulic oil to reservoir.

–2–5–

600, 600D, 610, 611 Loader Service Manual

2–2 TROUBLESHOOTING THE HYDRAULIC SYSTEM (Cont’d) PROBLEM

CAUSE

Lift arms drift with bucket empty.

Dirty check valve at the left control valve section.

Clean, check valve.

Lift control linkage is out adjustment.

Make adjustments of control linkage so spool centers correctly in the valve in neutral position.

Rough control valve movement.

CORRECTION

of

Ref.

The control pedals are rough because Lubricate and clean away old of no lubrication. grease.

The spool centering spring inside the valve is broken.

Install new spring.

Hydraulic cylinder leaks (internal).

38 of 216

1.

Clutch shaft caps.

2.

Gearcase side panels.

3.

Axle.

4.

Upper jackshaft.

5.

Lower jackshaft fastenings.

6.

Control lever pivots.

7.

Clutch shafts fasteners.

Check all bolts and nuts for looseness. Make repairs when there is leakage beyond seals or gaskets. Fill oil in reservoir to make up for lost oil.

Check all seals and replace any allowing oil loss.

Oil has been used to fill the hydraulic system of a new attachment.

Add new hydraulic oil.

Oil leak through hole on welded tank joint.

Check for leaks in the frame tanks and weld.

Oil is leaking beyond the lift or tilt cylinder shaft seals.

Install shaft seals and inspect the cylinder shafts for damage. Add new oil.

Loose hydraulic connections in the hydraulic systems.

Tighten the connections or install them when they don’t seal. Add new oil.

Oil is leaking through holes at the cylinder openings.

Remove the cylinder and weld holes. Add new oil.

Oil is leaking beyond the variable speed drive swivel seals.

Install seals. Add new oil.

Case is damaged, causing piston to wear flat and seal to leak oil.

Install new cylinder.

Case is rough beyond the piston at that point.

Install new cylinder case piston seals.

–2–6–

SEE SECTION 4

Loose of hydraulic fluid in hydraulic Oil may be leaking beyond any of these seals or gaskets: system, (external).

and

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

The control valve housing is out of line Fasten valve group with only the because of wrong fastening. three outside bolts, putting shims under the valve on the bolts to fasten it away from plate.

2–2 TROUBLESHOOTING THE HYDRAULIC SYSTEM (Cont’d)

Hydraulic cylinder leaks (external). The shaft is rough, causing oil loss along the shaft and bad seal.

CORRECTION

Ref.

Smooth shaft. Install shaft seals.

Add new oil.

There is oil line or fitting leak.

Tighten or install new fitting. Add new oil.

Hole in weld on fitting.

Remove, clean the cylinder. Weld around fitting. Add new oil.

Cylinder head leaks.

Install O–ring. Add new oil.

Hole in cylinder housing.

Remove the cylinder and weld.

Add new oil.

Seals are bad.

Smooth rod and install seal.

Hydraulic control valve leaks (external).

The valve body is broken.

Install the valve. Add new oil.

There is a hole in the valve housing.

Install new valve. Add new oil.

Hydraulic control valve leaks (internal).

The control linkage is out of adjustment.

Make adjustment of linkage so the spool is centered in the valve housing with the control pedal in neutral position.

The valve spool is marked.

Install new valve.

The valve body is marked.

Install new valve.

The load check valve will not seat correctly.

Clean and install any parts needed.

Running the variable speed at a constant high variable speedposition, holding pressure buildup in the cylinder can cause seal failure.

Do not run continuously at variable speed position.

Lift arm does not drift down, but drops when raised slowly.

The variable speed cylinder will not The plunger in the holding release hold in high speed position (on valve part of the control valve is too models equipped with variable long. It will not allow the check ball to speed control valve with holding seat. pressure release).

No change when the variable speed control lever is put in low speed position (on loaders with a check valve).

one

Put shims behind the cast spring holding bracket. Install .020’’ thick shims on fastening bolts. Make adjustment for release pressure of 600 PSI.

Worn O–rings in the plunger.

Install new O–rings.

There is a high holding pressure buildup in the variable speed cylinder.

Let the loader cool.

Dealer Copy -- Not for Resale

CAUSE

SEE SECTION 4

PROBLEM

Loosen the hydraulic hose fitting at the check valve to release some of the pressure.

Replace the variable speedcontrol valve with one having a pressure release valve.

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600, 600D, 610, 611 Loader Service Manual

2–2 TROUBLESHOOTING THE HYDRAULIC SYSTEM (Cont’d) PROBLEM Tilt control valve body split.

CAUSE

CORRECTION

Ref.

Casting stress due to changing shape of fastening plate.

Fasten valve group with only the three outside bolts, laying shims under the valve on the bolts to fasten it away from the plate.

Install new valve.

The release valve pressure is too high Lower the release setting to 1800 to 1900 PSI. in lift and auxiliary valve.

The bucket will not hold tilted back Oil leaks between the valve spool and Spool is worn or seals are bad. with the control in neutral position. the valve housing with the spool centered.

Check for external leaks correct.

and

Check for a bad spool or action.

rough

Check for a broken spool center spring in the valve.

Oil leaks between the valve spool and Install new valve. Check condition of the cylinder seals before the valve housing with the spool installing the valve. centering.

The lift cylinder seals are under a load.

The hydraulic oil filter condition indicator shows no reading at full engine RPM.

leaking

There is a hole in the filter element.

Install new filter element.

The cork and steel gaskets have not been installed on the ends of filter element during service.

Install new cork and steel gaskets.

The release valve in the filter container is holding open.

Check the release valve and clean it.

There is a leak in the vacuum (between the filter and gauge).

40 of 216

Install new seals.

line

Check all conditions for tightness.

The vacuum line (between the filter and gauge) is closed.

Open the line.

The hydraulic oil filter container has not been tightened.

Tighten the large nut on the end of the filter container to 12 ft.–lbs.

(1.7 m/kgf).

The condition indicator gauge is bad.

Install new gauge.

–2–8–

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

Make adjustment of control linkage so the spool will centerwith the pedal in neutral position.

SEE SECTION 4

The lift arms drift down from raised There is an external oil leak between position with the lift control pedal in the lift control valve and cylinders. neutral position.

The spool is not centering in the valve housing when the control pedal is released.

2–2 TROUBLESHOOTING THE HYDRAULIC SYSTEM (Cont’d) PROBLEM

CAUSE

CORRECTION

More than normal hydraulic pump wear (600 gasoline or LP gas models).

There is not enough clearance between the pump drive adapter halves, over maximum thrust on the pump drive shaft.

Make adjustment of adapter to hold .015 to .030 inches clearance between the adapter halves.

Rotate to check for even clearance.

Dirty hydraulic oil.

Empty reservoirs and fill with clean oil.

Pump drive out of alignment.

Make correct alignment.

Oil supply is low (hydraulic oil).

Fill the reservoir to the upper check opening.

Wrong grade oil.

Change to correct oil.

The oil filter is dirty.

Change the oil filter.

The suction tubeline (between the reservoir and pump) is stopped.

Remove and clean the tubeline.

There is an air leak between the reservoir and pump.

Inspect for and correct any air leaks.

Worn pump coupling.

Install new coupling.

Oil supply is low (hydraulic oil).

Fill the reservoir to the upper check opening.

The oil is dirty.

Empty the reservoir and fill clean oil.

The master release valve setting is low.

Check the pressure and set to proper release setting (1700 ± 25 psi), 119.5 ± 1.8 kgf/cm@).

Lift & auxiliary relief valve set low.

Hydraulic pump seal leaks.

Air in hydraulic oil.

with

Set to 1800 +100 psi (126.5 –0 kgf/cm@).

+7 –0

Wrong grade oil.

Empty the reservoir and change to correct weight oil.

Worn hydraulic pump.

Repair or install new pump.

Worn shaft seal.

Install new shaft seal.

Broken body seal or gasket.

Install new seal or gasket.

The bearings are out of position.

Install new bearings.

There is internal wear.

Install new parts.

The oil supply is low.

Fill the reservoir to the upper check openings.

Air is leaking into the suction side of pump.

Inspect all fittings and fasteners and tighten.

Dealer Copy -- Not for Resale

The hydraulic oil is heating.

suction SEE SECTION 4

Noise in hydraulic pump.

Ref.

Inspect to be sure the fittings on back of the vacuum gauge (hydraulic oil filter condition indicator) on the right dash panel are tight.

41 of 216

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600, 600D, 610, 611 Loader Service Manual

2–2 TROUBLESHOOTING THE HYDRAULIC SYSTEM (Cont’d) PROBLEM Air in hydraulic oil. (Cont’d)

CAUSE

CORRECTION

Air is leaking into the cushion side of pump. (Cont’d)

Inspect to be sure all connections at the hydraulic oil filter are tight.

Ref.

Using wrong oil.

Empty release and fill to upper check opening with correct oil.

Large amount of hydraulic pump coupling wear.

Alignment between engine and pump not correct.

Correct alignment.

Auxiliary or lift control pedals will not hold in overthe center position.

Wrong adjustment of control linkage.

Make correct adjustment of control linkage.

Hydraulic pressure gauge indicates less than 1650 (1 16 kgf/cm@) with pressure control valve open.

Master release valve setting is low.

Make adjustment of master release valve.

Master release valve is dirty.

Clean valve.

Hydraulic pump worn.

Install new pump.

Cartridge release setting in left and auxiliary control valve is low.

Make correct adjustment.

42 of 216

–2–10–

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

Check clutch manifold release valve for foreign material holding check valve open.

SEE SECTION 4

Check for air leaking into the hydraulic pump beyond the shaft seals and install the seals when leaking.

2–3 TROUBLESHOOTING THE ENGINE ENGINE TYPE D–Diesel, A–All, G–Gas

CODE

Engine will not turn over.

A

Bad fuse in the wiring.

Install new fuse.

5, 6, 7

A

Loose battery connection.

Clean battery terminals and connect cables, tightening them.

5, 6, 7

A

Battery is discharged.

Charge battery. Check charging system.

5, 6, 7

A

Bad starter switch.

Install new switch.

5, 6, 7

A

Loose starter connections.

Tighten connections.

5, 6, 7

A

Broken or disconnected harness.

Connect or repair wiring harness.

5, 6, 7

A

The variable speed is in high speed. Pull variable speed drive control lever all the way back before stopping engine.

5, 6, 7

A

The clutches are engaged with steering levers in neutral position.

The loader will move while starting.

Make adjustment of clutches so levers will travel 3 to 4 inches from neutral position, in each direction.

5, 6, 7

A

Starting procedure is not correct.

Refer to ‘ ‘Starting Procedure’’ in Bobcat Operation section of this manual.

5, 6, 7

A

No fuel in tank.

Put in fuel.

5, 6, 7

A

The engine air cleaner is dirty.

Service air cleaner.

5, 6, 7

A

The air vent hole in fuel tank cap is plugged.

Remove and clean cap.

5, 6, 7

A

Fuel line leaks.

Repair line.

5, 6, 7

A

Damaged fuel pump.

Repair or install new pump.

5, 6, 7

G

The carburetor is not being choked enough.

Choke as required.

5

G

The carburetor is being choked too much when starting a warm engine.

Correct choking procedures.

5

A

Water, dirt or foreign material in fuel. Drain and clean fuel system. Fill with clean fuel.

G

Dirty carburetor.

Clean carburetor.

5

G

The ignition cable is disconnected from magneto, distributor or spark plugs.

Connect ignition cable.

5

G

Broken ignition cables, cause short circuits.

Repair or install new cables.

5

Engine fails to start or is difficult to start.

43 of 216

CAUSE

CORRECTION

Ref. (Section)

PROBLEM

–2–11–

wiring

Dealer Copy -- Not for Resale

CODE

5, 6, 7

600, 600D, 610, 611 Loader Service Manual

2–3 TROUBLESHOOTING THE ENGINE (Cont’d) CODE

Engine fail to start or is difficult to start (Cont’d)

G

The ignition cables, distributor or spark plugs are wet.

Dry and clean them.

5

G

Moisture in ignition system due to fertilizer dust settling into or around switches, fuses, ignition wire, battery terminals or distributor cap.

Store idle loader in a dry place as far as possible from stored fertilizer.

5

Clean fertilizer dust off loader daily and wash it of f frequently with diesel fuel.

5

Spray ignition system with a sealant made to prevent moisture problems.

5

Engine fails to start or is difficult to start.

Engine runs rough.

Power is low . Engine may stop.

44 of 216

CAUSE

CORRECTION

G

The spark plugs are wet or dirty.

Clean or install new spark plugs.

1

G

the spark plug gaps are wrong.

Gap or install new.

1

G

The ignition is out of time.

Correct timing.

1

G

Bad condenser or coil.

Install new.

5

G

Bad distributor.

Repair or install new.

5

A

Wrong crankcase oil (coldweather).

Use an engine oil of proper viscosity.

5, 6, 7

A

The valves are leaking or sticking.

Clean and reseat the valves.

5, 6, 7

A

Valve tappets out of adjustment.

Make adjustment.

5, 6, 7

A

Cylinders dry due to engine having been out of use for some time.

Correct compression by pouring a small amount of engine oil into cylinders.

5, 6, 7

G

Loose spark plugs.

Install new gaskets and tighten.

1

A

Damaged cylinder head gasket or loose cylinder head.

Install new gasket and tighten.

5, 6, 7

A

Piston rings stuck in piston.

Clean the parts and install new rings.

5, 6, 7

A

Damaged cylinders (lack of compression).

Repair.

5, 6, 7

D

Air in the fuel system.

Bleed the system.

6, 7

A

Fuel filter is plugged.

Install a new element.

5, 6, 7

D

Faulty injector nozzle.

Check, clean and make adjustment.

6, 7

D

Faulty injector pump.

Make adjustment or install pump.

D

Wrong decompressor setting.

Make adjustment.

6, 7

D

Air in fuel lines.

Bleed the system.

6, 7

A

Water in the fuel system.

Empty fuel system. Fill with clean fuel.

5, 6, 7

–2–12–

new

6, 7

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

Ref. (Section)

PROBLEM

CORRECTION

Ref. (Section)

Air in fuel system.

Check for and correct leaks.

6, 7

D

Bad injector nozzle.

Check, clean and make adjustment.

6, 7

A

Fuel filter is plugged.

Install a new element.

5, 6, 7

A

Wrong valve clearance.

Make valve adjustment.

5, 6, 7

A

Broken valve spring.

Install a new spring.

5, 6, 7

G

Spark plug gap not correct.

Correct spark plug gaps.

1

D

Wrong decompressor setting.

Make adjustment.

6, 7

G

Wrong type spark plugs.

Check recommendations.

1

G

Wrong ignition timing.

Correct timing.

1

G

Bad spark plugs.

Clean or install new. Check cause.

1

G

Bad breaker points.

Check for cause and install new.

1

G

Loose ignition cables or worn or broken cables.

Repair or tighten or install new.

5

A

Poor compression.

Tighten cylinder heads and check gaskets.

5, 6, 7

G

Incorrect fuel mixture.

Make carburetor adjustment.

5

G

Dirty carburetor.

Clean.

5

A

Fuel screen fuel of foreign material.

Clean.

5, 6, 7

G

Carburetor flooding.

Check carburetor adjustment.

A

Governor out of adjustment.

Correct adjustment.

5, 6, 7

A

Sticking valves.

Free the valves.

5, 6, 7

A

Pitted valves.

Grind or install new.

5, 6, 7

A

Dirty engine (may be due to blocked Clean and clear. exhaust.

A

Wrong fuel.

Drain the fuel system and fill with clean correct fuel.

5, 6, 7

A

Dirty Air cleaner.

Service the air cleaner.

5, 6, 7

D

Incorrect fuel timing.

Make adjustment.

6, 7

A

Broken compression ring.

Check. Install new.

5, 6, 7

D

Excessive carbon on pistons and cylinder head.

Clean the carbon from the cylinder head and pistons.

6, 7

A

Worn cylinder and pistons.

Recondition the engine.

5, 6, 7

PROBLEM

CODE

Engine runs rough.

Power is low . Engine may stop.

D

Engine fails to start or is difficult to start.

45 of 216

CAUSE

–2–13–

5

Dealer Copy -- Not for Resale

2–3 TROUBLESHOOTING THE ENGINE (Cont’d)

5, 6, 7

600, 600D, 610, 611 Loader Service Manual

2–3 TROUBLESHOOTING THE ENGINE (Cont’d) Engine overheats.

CODE A

CORRECTION

Ref. (Section)

Operate at a lower variable speed set.

See Owner’s Manual

CAUSE Engine is overloaded.

Operate at a 3/4 tofull throttle setting.

Engine making hitting noise.

46 of 216

A

Engine cooling fins are dirty.

A

Engine has been operated with part Clean the cooling fins and install of the housing removed. housing.

1

A

Dirty engine oil.

Change engine oil.

1

D

Blower not operating.

Check drive.

6, 7

A

using wrong grade of engine oil.

Change to proper oil grade and viscosity oil.

1

A

The crankcase oil level is low.

Add oil.

1

A

Excessive valve clearance.

Make adjustment.

5, 6, 7

D

Restriction in exhaust.

Remove restriction.

6, 7

A

Engine is not being lubricated properly.

Check operation of engine oil pump.

5, 6, 7

D

Carbon in engine.

Clean the carbon from cylinderheads and pistons.

6, 7

D

Faulty injector nozzles.

Check, clean and make adjustment.

6, 7

D

Faulty injector pump.

Make adjustment or install new.

6, 7

A

Worn pistons.

Install new pistons.

5, 6, 7

A

Worn connecting rod bearings.

Install new bearings.

5, 6, 7

D

Loose flywheel.

Tighten or install when bore is damaged.

6, 7

A

Worn main bearings.

Install new main bearings. Check proper lubrication bearings.

5, 6, 7

A

Carbon on the pistons.

Clean the carbon from top of pistons and from cylinder heads.

5, 6, 7

D

Fuel timing is wring.

Make adjustment of timing.

6, 7

A

Broken piston ring.

Install a new ring or rings.

5, 6, 7

G

Poor grade of gasoline.

Use good grade gasoline.

1

A

Engine operated under heavy load Always operate at 3/4 to full throttle at low speed. setting.

–

A

Low oil supply.

Add oil.

1

A

Dirty oil.

Change oil.

1

G

Incorrect timing.

Making timing adjustment.

1

G

Wrong spark plugs.

Install correct spark plug.

1

A

Worn or loose piston pin.

Install new.

5, 6, 7

A

Worn main bearings.

Install new.

5, 6, 7

A

Excessive camshaft end clearance. Make adjustment.

–2–14–

Clean the cooling fins.

1

5, 6, 7 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

PROBLEM

2–3 TROUBLESHOOTING THE ENGINE (Cont’d) CORRECTION

Ref. (Section)

Make carburetor adjustment.

5

Carburetor jets dirty.

Clean.

5

G

Spark plug gap is small.

Make adjustment of gap.

1

G

Leaking carburetor or manifold gaskets.

Tighten or install new gaskets.

5

G

Dirty or leaking valves.

Clean and reseat valves.

5

G

Weak coil or condenser.

Install new.

5

A

Oil is light.

Empty, refill with correct oil.

1

A

Crankcase pressure.

Clean vent valve.

1

A

Worn piston rings.

Install new.

A

Crankcase overfilled.

Clean vent valve.

1

G

Fuel mixture.

Make adjustment of carburetor or choke.

5

G

Choke not open.

Inspect linkage and setting.

5

G

Dirty air cleaner.

Service the air cleaner.

1

G

Crankcase pressure.

Clean vent valve.

1

A

Bad indicator.

Install new indicator.

5, 6, 7

A

Oil is light.

Empty. Fill with correct oil.

1

A

Oil level low.

Add oil.

1

A

Dirt on oil screen.

Clean.

5, 6, 7

A

Badly worn oil pump.

Repair.

5, 6, 7

A

Incorrect oil pressure setting.

Make adjustment.

5, 6, 7

G

Leaking fuel pump.

Install new fuel pump.

5

A

Bad indicator.

Install new indicator.

5, 6, 7

A

Oil grade is heavy.

Empty. Refill with correct oil.

1

A

Oil lines dirty.

Clean all lines and openings.

5, 6, 7

A

Oil relief valve stuck.

Clean by–pass. Install needed.

5, 6, 7

CODE

Engine will not stop.

G

Improper adjustment.

G

Oil consumption. (Light blue exhaust smoke.)

Black exhaust smoke.

Excessive fuel used.

Spark plugs dirty.

Low oil pressure.

High oil pressure.

47 of 216

CAUSE carburetor

–2–15–

idling

5, 6, 7

when

Dealer Copy -- Not for Resale

PROBLEM

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

610,611ServiceManual#6556276–TroubleshootingSection

48 of 216

–2–16–

600, 600D, 610, 611 Loader Service Manual

DRIVE SYSTEM

49 of 216

–3––1–

DRIVE SYSTEM

Dealer Copy -- Not for Resale

Paragraph Page Number Number ASSEMBLY OF BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28 ..

3–28 ASSEMBLY OF DRIVEN SHEAVE (STRAIGHT JACKSHAFT) . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10 ..

3–14 ASSEMBLY OF DRIVEN SHEAVE (TAPERED JACKSHAFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8 ..

3–13 ASSEMBLY OF 610 VARIABLE SPEED W/ROTO–SWIVEL INSIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16 ..

3–17 AXLE BEARING AND SEAL INSTALLATION . . . . . . . . . . . . . .3–20 3–20 AXLE REMOVAL (FRONT AXLE) . . . . . . . . . . . . . . . . . . . . . .3–19 .

3–19 AXLE SPROCKET REMOVAL INSTALLATION . . . . . . . . . . . . 3–22 3–22 BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29 ..

3–29 BRAKE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–27 ..

3–28 CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 ..

3–2 DISASSEMBLY AND ASSEMBLY (CLUTCH) . . . . . . . . . . . . .3–2 3–2 DISASSEMBLY OF DRIVEN SHEAVE (STRAIGHT JACKSHAFT) . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9 ..

3–14 DRIVE BELT INSTALLATION (SPLIT SHAFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4 ...

3–9 DRIVE CHAIN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . .3–26 .

3–26 DRIVEN SHEAVE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . .3–11 .

3–14 DRIVEN SHEAVE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . .3–7 .

3–13 INSTALLATION OF AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21 ..

3–21 INSTALLATION OF DRIVEN SHEAVE . . . . . . . . . . . . . . . . . . 3–6 .

3–12 INSTALLING CLUTCH NEEDLE BEARINGS . . . . . . . . . . . . .3–3 3–9 JACKSHAFT BEARING INSTALLATION . . . . . . . . . . . . . . . . .3–12 3–15 LOWER JACKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . 3–25 .

3–24 LOWER JACKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . .3–23 .

3–23 LOWER JACKSHAFT SPROCKET REPAIR . . . . . . . . . . . . . .3–24 3–24 REMOVAL OF DRIVEN SHEAVE . . . . . . . . . . . . . . . . . . . . . . .3–5 .

3–11 REMOVAL OF FRAME SUPPORT VARIABLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–18 ..

3–18 REMOVAL OF VARIABLE DRIVEN SHEAVE WITH ROTO–SWIVEL INSIDE . . . . . . . . . . . . . . . . . . . . . . . .3–13 .

3–16 REMOVAL OF VARIABLE SHEAVE WITH ROTO–SWIVEL OUTSIDE . . . . . . . . . . . . . . . . . . . . . 3–17 .

3–18 ROTO–SWIVEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .3–15 .

3–17 ROTO–SWIVEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .3–14 .

3–17

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale 50 of 216

–3–0–

600, 600D, 610, 611 Loader Service Manual

Driven Sheave Assy.

Actuating Threads

Secondary Drive Chain

Dealer Copy -- Not for Resale

Actuating Nuts

Reverse Direction Clutch Assy.

Driven Sheave Assy.

Forward Direction Clutch Assy.

Primary Drive Chain

Final Drive Chain

PI–01127

Fig. 3–1 Clutch Drive System Breakdown (Right Side Shown)

51 of 216

–3–1–

600, 600D, 610, 611 Loader Service Manual

SERVICE FOR DRIVE SYSTEM 610,611ServiceManual#6556276–DriveSystemSectionPages1–2

3–1 CLUTCH ADJUSTMENT The Bobcat has two drive systems, one on each side of the loader, each equipped with two clutches. The front clutch on each side of the loader is the reverse direction clutch and the rear clutch is the forward direction clutch (Fig. 3–1).

1

PI–01026

Fig. 3–2 Clutch Adjustment Adjustment Procedure

2. Use the large clutch cap wrenchto remove the caps from the clutch shafts (Fig. 3–2, (Item 1).

3. Remove the cotter pins which hold the castle nuts in place (Fig. 3–3).

4. Put control levers in neutral position (Fig. 3–2).

5. Adjustment is correct for reverse clutch position when top of lever can be moved 3–4 inches from neutral to full engaged reverse position (Fig. 3–2).

B–02414

Fig. 3–3 Removing Cotter Pin

C–01779

Fig. 3–4 O–ring In cap

6. To make correct adjustment use small end of the clutch wrench to tighten or loosen front castle nut (Fig. 3–2).

7. Adjustment is correct for forward clutch position when top of lever can be moved 3–4 inches from neutral to full engaged forward position (Fig. 3–2).

8. Makes same adjustment as Step 6 & 7 to rear castle nut.

B–02023

Fig. 3–5 Remove Side Cover

9. Make same adjustments to both sides of loader . Then check control levers for even alignment in all positions (Fig. 3–2, Item 2).

10. Install cotter pin in each castle nut (Fig. 3–3).

11. Inspect quad–ring in cap and put oil on quad–ring before installing cap (Fig. 3–4).

12. Install cap and tighten (Fig. 3–2).

52 of 216 Added February 80

–3–2–

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

1. Stop the engine.

3–1a Steering Clutch Adjustment

If steering of the loader is difficult or the clutches do not engage correctly, check the five items below: Weld Nut On Cap

A–01638

Fig. 3–5a Pulling Rool

B–01545

Fig. 3–5b Removing Bend in Side Panel

Turned Around

Dealer Copy -- Not for Resale

1. Stop the engine and move the steering levers. Check the side covers to see if they have movement. If there is movement the cover has a bend in it. Make a tool for pulling the cover out by drilling a hole in a clutch cap and welding a nut to it (Fig. 3–5a).

Remove the cotter key and castle nut from clutch pin. Install the tool (Fig. 3–5b) enough to pull the cover out.

2. Remove the side cover . Turn clutch nut around and assemble the self–aligning race parts as shown (Fig. 3–5c). Make an adjustment of the steering linkage and move the levers. If lever action is now positive, the self–aligning race parts have a defect (Fig. 3–5d).

B–02278

Fig. 3–5c Reversing Clutch Nut

Metal Particle

A–02418

Fig. 3–5d Clutch Nut (Cross Section) 53 of 216 Added February 80

–3–2a–

A–01518

Fig. 3–5e Actuating Nut (Cross Section) 600, 600D, 610, 611 Loader Service Manual

3. The actuating nut, self–aligning nut, and outside clutch plates must be checked to see if the bearing race is in place (Fig. 3–5e, 3–5f, 3–5g). The race must be installed so you cannot put a feeler gauge under the race (Fig. 3–5h, 3–5i). The race must make even contact against the clutch plate.

Make corrections as necessary.

610,611ServiceManual#6556276–DriveSystemSectionPages2a–2b

B–02283

Fig. 3–5f Bearing Seat On Clutch Plate 4. Check the fit of the threads in the actuating nuts. If any are loose or have wear, install new actuating nuts. The new actuating nuts must be hard (Fig. 3–5j).

5. Check the clutch plates to see that the surfaces are flat by using a feeler gauge. Remove the lining from between the clutch plates and hold the plates together by hand. If there is clearance any place on the surface of the clutch plate replace the damaged clutch plate (Fig. 3–5k).

A–01517

Fig. 3–5g Clutch Nut (Cross Section)

A–01515

Fig. 3–5h Checking Actuating Nut Blue Color From Heat Treatment

Feeler Gauge Fig. 3–5i Checking Clutch Nut

A–01516

A–02419

Fig. 3–5j Actuating Nut

Feeler Gauge

B–02281

Fig. 3–5k Clutch Check 54 of 216 Added February 80

–3–2b–

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

Feeler Gauge

Metal Particle

3–2 DISASSEMBLY & ASSEMBLY Disassembly 1. Remove tires and put machine on blocks. Remove clutch caps (Fig. 3–2).

2. Remove side cover (Fig. 3–5).

B–02416

3. Loosen the primary chain idler and remove primary drive chain (Fig. 3–6).

Fig. 3–7 Remove Castle Nut

castle

5. Remove caste nut (Fig. 3–7).

6. Remove alignment nut (Fig. 3–8).

PI–01128

7. Remove thrust bearing and race (Fig. 3–8).

Fig. 3–8 Remove Alignment Nut, Race and Bearing

8. Remove outside clutch plate (Fig. 3–9).

Dealer Copy -- Not for Resale

4. Remove cotter pins from nuts (Fig. 3–3).

Fig. 3–6 Remove Idler For Primary Drive Chain

B–02415

9. Remove clutch lining (Fig. 3–9).

10. Remove sprocket from secondary idler (Fig. 3–10).

B–01946

Fig. 3–9 Remove Clutch Plate and Lining

11. Remove inside clutch plate, hardened race and thrust bearing (Fig. 3–11).

PI–01130

Fig. 3–10 Remove Secondary Idler Sprocket 55 of 216 Revised February 80

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PI–01131

Fig. 3–11 Remove Inside Clutch Plate 600, 600D, 610, 611 Loader Service Manual

12. Remove seal and engine cover (Fig. 3–12).

13. Remove four hydraulic lines clutch shafts (Fig. 3–13).

to

14. Remove clutch shaft holding nut (Fig. 3–14).

15. Remove internal lock washer and lead seal (Fig. 3–14).

17. Remove center spring (Fig. 3–15).

C–01784

Fig. 3–12 Remove Seat and Engine Cover

PI–01132

Fig. 3–13 Remove Hydraulic Lines

C–01803

Fig. 3–14 Remove Clutch Shaft Holding Nut

B–01830

Fig. 3–15 Remove Actuator Linkage and Spring 56 of 216 80 Revised February

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600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

16. Remove clutch actuator linkage (Fig. 3–15).

18. Remove clutch shaft and actuator bar (Fig. 3–16).

Assembly

1. Install clutch actuator nuts to actuator linkage.

PI–01133

a. Hold actuator linkage in same position as when it is installed in loader (Fig. 3–17).

Fig. 3–16 Remove Clutch Shaft and Actuator Bar

b. Put the right hand thread actuator nut into the rightyoke and the left hand thread actuator nut into the left yoke (Fig. 3–17).

Dealer Copy -- Not for Resale

c. Install spring washers behind eye of yokes and install on actuator bar. Washer must fit over shoulder of screw (Fig. 3–18).

B–02594

d. Turn clutch actuator nuts.

shafts

into

Fig. 3–17 Install Actuator Nuts

2. Install assembly into loader. a. Hold right clutch shaft in right hand and left clutch shaft in left hand (Fig. 3–19). b. Place the system in clutch shaft holes (Fig. 3–19).

B–01828

Fig. 3–18 Install Spring Washers

PI–01133

Fig. 3–19 Install Clutch Shaft and Actuator Bar 57 of 216

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c. Install new lead seals over clutch shaft threads. Form lead washers using tool P/N 4127904.

d. Turn clutch shaft holding nuts onto clutch shaft.

e. Tighten clutch shaft nuts so shaft will not turn by hand pressure (Fig. 3–20).

Fig. 3–20 Tighten Holding Nuts

Connect actuator linkage to lever linkage (Fig. 3–21).

3. Make adjustment of clutch shaft for positive clutch engagement. a. Put direction control lever 3–4 inches forward of neutral positron (Fig. 3–22). b. Turn rear clutch shaft for full thread contact between activating threads (Fig. 3–22).

B–01830

Fig. 3–21 Connect Actuator Linkage to Lever Linkage WITH THE CONTROL LEVER HAND GRIP 4’’ FORWARD OF NEUTRAL, THE REAR ACTUATING NUT AND THREAD SHOULD HA VE ‘‘FULL THREAD CONTACT’’ AS SHOWN.

4’’

c. To turn clutch shaft, install castle nuts onto clutch shaft with castle toward the loader.

Put cotter pins through castle nut and shaft. Use wrench on nut to turn shaft.

FULL THREAD CONTACT d. When rear clutch shaft has correct adjustment, tighten the clutch shaft holding nut to 225 foot–pounds (305 Nm).

Use a wrench on castle nut to prevent clutch shaft from turning. Install inside clutch plate over rear shaft.

PI–01134

FULL THREAD CONTACT WRONG

RIGHT

WRONG

PI–01135

Fig. 3–22 Adjusting Clutch Shaft 58 of 216 80 Revised February

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600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

f.

C–01803

e. Put grease on thrust bearing to hold it in hub.

Install inside clutch plate (Fig. 3–23).

g. Put front clutch plate in alignment with rear clutch plate with control levers in neutral position. to check use a straight edge across face of clutch plate (Fig. 3–24). T urn front clutch shaft for alignment. When alignment is correct hold clutch shaft and tighten holding nut to 225 foot–pounds (305 Nm).

Thrust Bearing

Thrust Washer PI–01131

Fig. 3–23 Install Inside Clutch Plate

4. Install secondary idler sprocket (Fig. 3–25).

5. Install secondary chain over idler sprocket under sprocket on front clutch and over sprocket on rear clutch (Fig. 3–26).

PI–01136

Fig. 3–24 Alignment Of Clutch Plates

6. Connect chain with press fit connectors (Fig. 3–27).

Dealer Copy -- Not for Resale

f.

7. Tighten chain for 1/4 inch playwith hand pressure.

PI–01130

Fig. 3–25 Install Secondary Idler 8. Install clutch linings to inside clutch plates. Lining should fit loosely over shoulder of inside clutch (Fig. 3–28).

Lining

PI–01191

Fig. 3–27 Install Chain Connector 59 of 216

PI–01190

Fig. 3–26 Install Secondary Chain

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Shoulder

B–01946

Fig. 3–28 Install Clutch Lining 600, 600D, 610, 611 Loader Service Manual

9. Install outside clutch plates (Fig. 3–29).

10. Install thrust bearings and thrust races on outside clutch plates (Fig. 3–30).

11. When installing new thrust bearings, also install new thrust races for bearings. Check Parts Manual to get correct races used with heavy bearings.

PI–01129

Fig. 3–29 Install Outside Clutch Plate

PI–01128

Fig. 3–30 Install Thrust Bearing & Race

13. Install alignment nut (Fig. 3–30).

PI–01137

Fig. 3–31 Check Alignment Nuts

B–02414

Fig. 3–32 Install Castle Nuts & Roll Pins

14. Install castle nut (Fig. 3–32).

15. Use straight–edge to check alignment of clutch sprockets with primary drive sprocket (Fig.3–33).

16. Install primary drive chain with 1/4’’ (6.4 millimeter) play at 10 pounds (4.5 kilogram) of pressure (Fig. 3–34).

PI–01138

Fig. 3–33 Check Clutch Sprocket Alignment

PI–01140

Fig. 3–34 Check Primary Drive Chain

17. Install side panel (Fig. 3–35).

18. Check control lever movement (Fig. 3–36). Adjust clutches see Page 3–2.

B–02023

Fig. 3–35 Install Side Panel 60 of 216 80 Revised February

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PI–01026

Fig. 3–36 Check Control Lever Movement 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

12. Check alignment nut so it moves free by finger pressure. When not free, put in vise to press loose(Fig. 3–31).

19. Install clutch caps.

20. Install hydraulic lines to clutch shafts (Fig.. 3–37).

21. Install seat and engine cover.

3–3 INSTALLING CLUTCH NEEDLE BEARINGS. 1. Remove clutches. (See Page 3–32).

PI–01132

Fig. 3–37 Install Hydraulic Lines

2. Remove old bearings (Fig. 3–38).

3. Press a new bearing in from each side of clutch plate with numbered end of bearings to outside on each end of hub.

3–4 DRIVE BEL T INSTALLATION (Split Shaft) (On loaders equipped with canopy (ROPS) see 1 and 2, ‘ ‘Removal of Driven Sheave’’, page 3–11).

Dealer Copy -- Not for Resale

4. Bearing ends should be even with edge of hub (Fig. 3–39).

PI–01279

Fig. 3–38 Remove Old Bearings

Fig. 3–39 Bearing Installed

1. Put belt in low speed position (Fig. 3–40).

2. Remove outside half of variable speed drive sheave and hydraulic assembly (Fig. 3–41).

3. Clean cylinder and hose.

4. Disconnect hose fittings and seal off cylinder inlet and hose to keep out dirt.

5. Inspect spacer between variable speed cylinder and holding bracket and frame bracket. When installing, install spacers in same position as when removed (Fig. 3–42).

B–01959

PI–01142

Fig. 3–40 Drive Belt In Low Speed Position

Fig. 3–41 Variable Speed Drive Sheave

Spacer

6. Loaders with swivel coupler , remove swivel then remove holding nut to split sheave (Fig. 3–43).

D–01053

Fig. 3–42 Variable Speed Spacers 61 of 216

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C–01242

Fig. 3–43 Variable Speed Swivel Coupler 600, 600D, 610, 611 Loader Service Manual

7. Remove spilt jackshaft connector block (Fig. 3–44). Install in same position as removed.

Check punch marks and put toward sheave.

8. Remove old belt between split in shaft (Fig. 3–45).

9. Install new belt between split in shaft.

PI–01143

Fig. 3–44 Remove Connector Block

B–01966

Fig. 3–45 Removing Drive Belt

11. Use a round rod to pull belt onto drive sheave (Fig. 3–46).

12. Make adjustment of spring tension on driven sheave.

PI–01144

B–01965

Fig. 3–46 Install Belt On Drive Sheave

Fig. 3–47 Alignment Of Sheaves Halves

13. Install outside half of drive sheave.

Replace the holding nut and tighten to 130 (176 Nm) foot–pounds torque (Fig. 3–41).

WITH BELT AT HALF VARIABLE LAY A STRAIGHTEDGE ALONG THE DRIVEN SHEAVE AS SHOWN

14. Inspect alignment of balance marks on sheaves (Fig. 3–47).

15. Connect hydraulic hose.

16. Check alignment of sheaves (Fig. 3–48).

PI–01027

Fig. 3–48 Check Alignment Of Sheave

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Dealer Copy -- Not for Resale

10. Install split jackshaft connector block. Use new lock nuts. Tighten bolts evenly to 18–20 foot–pounds (27 Nm).

3–5 REMOVAL OF DRIVEN SHEAVE 1. Raise lift arms and install cylinder support bracket. Remove drive belt (Page 3–9).

2. Remove rear bolts from canopy and tilt canopy forward onto a support (Fig. 3–49).

3. Remove clutch caps from left side of loader (Fig. 3–2).

B–01537

Fig. 3–49 Tilting The Canopy

4. Remove left side panel (Fig. 3–5).

5. Loosen the primary idler and remove chain (Fig. 3–6).

7. Remove hydraulic line to left rear clutch shaft.

8. Remove the battery.

PI–01145

Fig. 3–50 Removing Sprocket

9. Remove hydraulic tubeline(s) from variable speed valve.

10. Loosen set screw in bearing locking collar (Fig. 3–51).

11. Remove bearing locking collar from jackshaft by rotating 3/4 turn (Fig. 3–52).

12. Remove jackshaft connector block. (Check position of block when making installation (Fig. 3–44).

PI–01146

Fig. 3–51 Loosening Set Screw

Dealer Copy -- Not for Resale

6. Use puller to remove drive sprocket of primary drive (Fig. 3–50).

PI–01147

Fig. 3–52 Remove Locking Collar

13. Drive jackshaft half toward center of loader with soft hammer (Fig. 3–53).

14. Remove jackshaft with sheave through top of machine (Fig. 3–54).

PI–01151

Fig. 3–53 Removing Jackshaft 63 of 216

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PI–01152

Fig. 3–54 Jackshaft And SheaveRemoval 600, 600D, 610, 611 Loader Service Manual

3–6 INSTALLING OF DRIVEN SHEAVE 1. Put sheave and jackshaft half into loader (Fig. 3–54).

2. Install a variable speed belt over the jackshaft (Fig. 3–45).

3. Install connector block punch marked ends together (Fig. 3–44).

4. Use new lock nut and tighten evenly to 18–20 foot–pounds (27 Nm).

C–01782

Fig. 3–55 Install Drive Sprocket

5. Install outside drive sheave half.

6. Inspect alignment of balance marks and connect hydraulic hose (Fig. 3–47).

7. Install sprocket on end of jackshaft (Fig. 3–55).

9. Install primary drive chain (Fig. 3–27).

10. Primary chains should be tightened to 1/8’ ’ (3,0 mm) play with light hand pressure (Fig. 3–34).

PI–01149

Fig. 3–56 Check Alignment Of Sprockets

11. Install side panels (Fig. 3–35).

12. Install clutch caps.

13. Check alignment of drive and driven sheaves (Fig. 3–48) a. When not in alignment put variable speed belt to half speed position. b. Stop engine. c. Loosen set screws on hub of stationary half of sheave.

Move sheave for alignment (Fig. 3–57).

B–02682

Fig. 3–57 Adjustment Of Driven Sheave

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Dealer Copy -- Not for Resale

8. Check alignment of sprocket with outside clutch sprocket (Fig. 3–56).

3–7 DRIVEN SHEAVE DISASSEMBLY Plate

Remove sheave and shaft from loader (tapered jackshaft) (see page 33) 1. Remove lubricant fitting (Fig. 3–58).

2. Remove three spring retainer nuts and plate (Fig. 3–58).

4. Remove moveable half of sheave from shaft (Fig. 3–58).

5. Remove sheave retaining (Fig. 3–58).

Retainer Nut Set Screw

3. Remove spring (Fig. 3–58).

Roll Pin

C–01015

Fig. 3–58 Driven Sheave Breakdown

nut

6. Remove stationary sheave half by holding shaft and hitting end on a block of wood (Fig. 3–59).

1. Drive the shaft into tapered hole on stationary half of sheave (Fig. 3–60).

2. Check to see that key is in place.

3. Install retainer nut. Tighten to 130 foot–pounds (176 Nm).

PI–01154

Fig. 3–59 Remove Sheave Half

PI–01155

Fig. 3–60 Install Shaft

4. Install moveable half of a sheave on shaft. Inspect seals and bushings (Fig. 3–61).

5. Install spring and retainer plate (Fig. 3–61).

Dealer Copy -- Not for Resale

3–8 ASSEMBLY OF DRIVEN SHEAVE (TAPERED JACKSHAFT)

6. Loosen nut on one guide bolt to start spring retainer nut overplate.

(Use new lock nuts, (Fig. 3–62).

7. Tighten nut to its original position.

8. Install other spring retainer nuts then tighten nuts until they are even with ends of bolts (Fig. 3–63). (Use new lock nuts.)

C–01851

Fig. 3–61 Spring And Retainer Plate

PI–01156

Fig. 3–62 Install Spring Retainer Plate

9. Install lubricant fitting and turn spring to position as shown in Figure 3–64.

C–01798

Fig. 3–63 Tighten Nuts 65 of 216

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PI–01157

Fig. 3–64 Install Spring And Fitting 600, 600D, 610, 611 Loader Service Manual

3–9 DISASSEMBLY OF DRIVE SHEAVE (STRAIGHT JACKSHAFT) After removal from Loader (See page 3–11) 1. Remove lubrication fitting.

2. Remove three retainer nuts (Fig. 3–58).

3. Remove spring.

4. Separate sheave.

3–10 ASSEMBLY OF DRIVEN SHEAVE (STRAIGHT JACKSHAFT) 1. Inspect seals and bushing on sheave.

2. Install movable half of sheave (Fig. 3–65).

B–01958

Fig. 3–65 Movable Half of Sheave

3. Install spring (Fig. 3–61).

Dealer Copy -- Not for Resale

4. Loose nut on one guide bolt to start spring retainer nut (use new lock nuts) (Fig. 3–62).

5. Tighten nut to its original position.

6. Install other spring retainer nuts then tighten until all are even with end of bolts (Fig. 3–63). (Use new lock nuts.)

7. Install lubrication fitting (Fig. 3–64).

3–11 DRIVEN SHEAVE ALIGNMENT Instructions for tapered jackshaft.

1. Remove clutch caps.

B–01960

2. Remove left side panel.

Fig. 3–66 Remove Connector Block

3. Remove primary chain.

4. Remove sprocket retainer bolt and use puller to remove sprocket from end of jackshaft.

WITH BELT AT HALF VARIABLE LAY A STRAIGHTEDGE ALONG THE DRIVEN SHEAVE AS SHOWN

5. Loosen set screws in locking collar.

6. Remove bearing collar by turning it in opposite direction of shaft rotation.

7. Remove nuts from connector block (Fig. 3–66).

8. Move jackshaft for alignment (Fig. 3–67).

9. Use new lock nuts on connector block and tighten to 18–20 foot–pounds (27 Nm) (Fig. 3–66).

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Fig. 3–67 Sheave Alignment –3–14–

600, 600D, 610, 611 Loader Service Manual

10. Check alignment again.

11. Install bearing locking collar.

12. Tighten set screws in collar.

13. Install jackshaft sprocket.

14. Use washers for alignment of drive sprocket with outside clutch sprocket.

(Fig. 3–56).

15. Install retainer washer and bolt.

16. Install primary chain.

B–02571

17. Tighten chain to 1/4 inch (6.4 mm) free play.

Fig. 3–68 Remove Bearing Housing Nuts

18. Install side cover.

19. Install clutch caps.

3–12 JACKSHAFT BEARING INSTALLATION 1. Remove clutch caps.

3. Remove primary chain.

4. Remove sprocket retainer bolt.

5. Use pullers to remove drive sprocket from end of jackshaft.

Dealer Copy -- Not for Resale

2. Remove side panels.

B–02579

6. Loosen set screws from locking collar.

Fig. 3–69 Remove Bearing Housing

7. Remove bearing locking collar by turning opposite of shaft rotation 8. Remove four nuts holding bearing housing (Fig. 3–68).

9. Remove bearing and housing from shaft (Fig. 3–69).

10. Remove bearing from housing (Fig. 3–70).

11. Install new bearing vertically into housing. Check to see that bearing moves free in housing (Fig. 3–71).

12. When bearing will not move free make replacement of housing.

13. Check rotation of bearing in housing (Fig. 3–70).

14. Inspect to see that offset hub of bearing is toward outside of loader (Fig. 3–72).

PI–01150

Fig. 3–70 Remove Bearing From Housing

15. Install housing to inner side of chain housing. Use new sealing washers (Fig. 3–69).

16. Install bearing locking collar and turn with shaft rotation to tighten.

17. Tighten set screws in collar.

18. Install sprocket on jackshaft.

19. Install sprocket retain or bolt.

20. Install primary chain.

21. Install side panel.

22. Install clutch caps.

A–01104

Fig. 3–71 Install Bearing Vertically 67 of 216

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PI–01150

Fig. 3–72 Check Offset Hub Position 600, 600D, 610, 611 Loader Service Manual

3–13 REMOVAL OF V ARIABLE DRIVE SHEAVE WITH ROTO SWIVEL INSIDE (600, 610 Gasoline and Diesel, Serial Number 72319 and Up)

1

1. While engine is running move variable speed control lever forward, then stop engine.

2. After engine has stopped, hold lever to rear and pullingup on drive belt to open drive sheave.

3. Remove round side cover by variable speed sheave.

2

4. Press in on the end cap (Fig. 3–73, Item 1) and remove snap ring (Item 2).

5. Slide the moving half sheave of f the stationary half sheave.

B–01831

Fig. 3–73 Remove Outer Half Sheave Snap Ring

Dealer Copy -- Not for Resale

6. Remove the large snap ring and pull the piston with swivel out of the stationary half sheave (Fig. 3–74).

7. Remove bolt and holding washer from end of variable speed (Fig. 3–75).

8. Remove washer from bolt.

9. Install bolt in crankshaft and turn until it hits the bottom.

10. Install 1/4 inch (6.4 mm) bolts into holes in fixed sheave hub.

11. Install puller on half sheave behind bolts and remove (Fig. 3–76).

12. Remove stationary half sheave from engine crankshaft.

B–01829

Fig. 3–74 Remove Piston With Swivel

PI–01158

Fig. 3–75 Remove Bolt and Washer 68 of 216

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PI–01160

Fig. 3–76 Remove Stationary HalfSheave 600, 600D, 610, 611 Loader Service Manual

3–14 ROTO–SWIVEL DISASSEMBLY 1. Remove snap ring that holds roto–swivel into the piston (Fig. 3–77, Item 1) 2. Remove roto–swivel (Fig. 3–77, Item 2).

1

2

5 3

4

3. Remove snap ring on end of roto–swivel (Fig. 3–77, Item 3).

4. Inspect two ball bearings.

5. Inspect end of roto–swivel.

3–15 ROTO–SWIVEL ASSEMBLY 1. Install roto–swivel seals (Fig. 3–77, Item 4) 2. Install two ball bearings (Fig. 3–77, Item 5).

B–01114

Fig. 3–77 Roto–Swivel Parts

4. Install roto–swivel into piston.

5. Install snap ring that holds roto–swivel into piston (Fig. 3–77, Item 1).

6

5

2

4 1

3–16 ASSEMBLY PROCEDURES FOR 610 V ARIABLE SPEED WITH ROTO–SWIVEL INSIDE

3

1. Install piston to stationary half sheave (Fig. 3–78, Item 1).

2. Install internal snap ring (Fig. 3–78, Item 2) 3. Install stationary half sheave on engine shaft.

Dealer Copy -- Not for Resale

3. Install snap ring on end of roto–swivel (Fig. 3–77, Item 3).

C–01342

Fig. 3–78 Variable Speed W/Inside Swivel

4. Remove 1/4 inch (6.4 mm) bolts in holes on stationary half sheave.

5. Remove bolt in crankshaft.

6. Put machined washer on bolt. (Inspect and make sure to use correct machined washer.)

7. Install bolt and washer (Fig. 3–78, Item 3).

8. Install moving half sheave (Fig. 3–78, Item 4).

9. Install end cap (Fig. 3–78, Item 5).

10. Push moving half sheave in and install snap ring (Fig. 3–78, Item 6).

11. Install hose to control valve and roto–swivel.

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3–17 REMOVAL OF V ARIABLE SHEAVE WITH ROTO–SWIVEL OUTSIDE (600 Gasoline, LP and Diesel; Serial Number 67253–72318) 2

1. While engine is running move variable speed control lever forward, then stop engine.

1

2. After engine has stopped, hold lever to rear and pull up on drive belt to open drive sheave.

3. Remove round side cover by variable speed sheave. Remove hydraulic hose from Roto Swivel.

C–01242

Fig. 3–79 Variable Speed W/Outside Swivel

4. Push in on movable half sheave so that snap ring can be removed (Fig. 3–79, Item 1).

5. After snap ring has been removed pull movable half sheave, with piston assembly, out of loader.

To install variable sheave reverse the above procedure. Always use new O–ring seals, lubricated with oil, when assembling variable speed parts.

3–18 REMOVAL OF FRAME SUPPORT V ARIABLE SHEAVE (600 Gasoline and LP; serial Number 62796–67252) 1. With engine running move variable speed control lever forward then stop engine. After engine has stopped move lever back to release hydraulic pressure.

2. Remove the hydraulic hose from variable speed assembly.

2

3. Remove the support bracket for variable speed and pull complete assembly with movable half sheave out of loader (Fig. 3–80).

Fig. 3–80 Variable Speed (600 Gas & LP)

1

3

4. Remove holding bolt and washers from end of crankshaft (Fig. 3–81, Item 1).

5. Use puller tool to remove stationary half sheave.

C–01016

Fig. 3–81 Variable Speed Frame Support

6. To disassemble piston assembly, use a driver to force cylinder shaft out of bearing cap (Fig. 3–81, Item 2).

7. Loosen clamp and remove rubber cover and plate.

8. Unscrew gland (Fig. 3–81, Item 3) and remove piston assembly.

To install variable sheave reverse the above procedure. Always use new O–ring seals, lubricated with oil, when assembling variable speed parts.

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6. Remove holding bolt and washer from end of crankshaft (Fig.3–79, Item 2).

Use puller to remove stationary half sheave.

3–19 AXLE REMOV AL AXLE)

(FRONT

1. Lift side of loader from which axle is to be removed (Fig. 3–82).

2. Empty oil from side tank reservoir (Fig. 3–83).

3. Disconnect linkage from control pedals (Fig. 3–84).

4. Remove floor panels and pedal guard (Fig. 3–85).

B–02573

Fig. 3–82 Raising Loader

B–01507

Fig. 3–83 Reservoir Oil Drain Plug

5. Remove wheel from axle.

6. Remove clutch caps.

7. Remove side panel.

9. Loosen final drive chains (Fig. 3–87).

10. Remove dust cap at end of axle (Fig. 3–88).

11. Remove cotter pin from castle nut and remove castle nut bushing and washer (Fig. 3–89).

C–01781

Fig. 3–84 Remove Pedal Linkage

C–01780

Fig. 3–85 Remove Floor Panels

PI–01162

Fig. 3–86 Secondary Drive chain

PI–01165

Fig. 3–88 Remove Hub Cap 71 of 216

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8. Loosen secondary drive chain (Fig. 3–86).

PI–01163

Fig. 3–87 Final Drive Chain

PI–01166

Fig. 3–89 Remove Nut, Bushing & Washer 600, 600D, 610, 611 Loader Service Manual

12. Loosen sprocket holding nut with axle wrench by installing two bolts in end of axle and turning axle with bar (Fig. 3–90).

13. Remove four nuts from outside axle housing (Fig. 3–91).

14. Pull axle from loader using puller (Fig. 3–92).

15. Remove sprocket nut and lock washer from loader (Fig. 3–93).

PI–01171

Fig. 3–90 Remove Sprocket Holding Nut

16. Remove final drive sprocket from loader.

1. Remove housing from axle by hitting end of axle against a wood block (Fig. 3–94).

2. Remove axle bearing from shaft use puller (Fig. 3–95).

PI–01169

Fig. 3–91 Remove Hub Nuts

B–01623

Fig. 3–92 Remove Axle

3. Install new bearing and seal in housing (Fig 3–96).

PI–01173

Fig. 3–93 Sprocket Nut & Locking Washer

PI–01174

Fig. 3–95 Remove Axle Housing 72 of 216

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PI–01169

Fig. 3–94 Remove Axle Housing

PI–01170

Fig. 3–96 Install New Bearing & Seal 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

3–20 AXLE BEARING AND SEAL INSTALLATION

4. Check that seal lips are forwards inside, seal should be even with outer edge of hub (Fig. 3–99).

Gasket

Seals

Sprocket Nut

Locking Washer

5. Use a pipe larger than axle shaft to drive housing and bearing on shaft (Fig. 3–100).

6. Install bushing on axle (Fig. 3–97 or Fig. 3–98) 3–21 INSTALLATION OF AXLE

C–01007

Fig. 3–97 Rear Axle Breakdown

1. Install final drive sprocket in drive housing (Fig. 3–101).

2. Install axle into loader (Fig. 3–102) 3. Install locking washer and holding nut on the axle.

Dealer Copy -- Not for Resale

Brake Hub

C–01607

Fig. 3–98 Front Axle Breakdown (Loaders with Brakes)

PI–01175

Fig. 3–99 Check Position of Seal

Fig. 3–100 Install Hub and Bearing

C–01805

Fig. 3–101 Install Final Drive Sprocket 73 of 216

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C–01804

Fig. 3–102 Install Axle 600, 600D, 610, 611 Loader Service Manual

4. Check that holding nut threaded part is away from sprocket (Fig. 3–103).

5. Inspect locking washer for diameter as front and rear are different (Fig. 3–104).

1.46”

1.37”

Rear Axle

Front Axle

No Thread Area

6. Install outside housing to loader frame (Fig. 3–105).

7. Begin installation of sprocket holding nut tighten by hand.

8. Install inside bearing, bushingand washer (Fig. 3–106).

A–02438

Fig. 3–103 Position Of Sprocket Nut

A–02437

Fig. 3–104 Locking Washer Diameter

9. Install castle nut onto end of axle and tighten until bearing hassome preload. (Turn axle to feel pre–load). (Fig. 3–107).

11. Use axle wrench to hold nut and turn axle to tighten against sprocket inside gear housing (Fig. 3–109).

12. Lock locking nut with lock washer (Fig. 3–110).

PI–01167

Fig. 3–105 Install Housing Frame

PI–01176

Fig. 3–106 Installing Inner Bearing

13. Tighten all chains (refer to drive chain adjustment).

14. Install side panel.

15. Install clutch caps.

16. Install floor panels (Fig. 3–85).

17. Connect control pedal (Fig. 3–84).

linkages

3–22 AXLE SPROCKET REMOVAL & INSTALLATION

B–02412

Fig. 3–107 Check Bearing Pre–Load

PI–01165

Fig. 3–108 Install Dust Cap

Follow steps in axle removal and axle installation. Check new sprocket for number of teeth and length of spline against old sprocket to be sure of correct replacement.

B–02418

Fig. 3–109 Tightening Sprocket Nut 74 of 216

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PI–01278

Fig. 3–110 Bending Locking Washer 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

10. Install cotter pin and dust cap on inside end of axle. Inspect O–ring in cap and make replacement if damaged (Fig. 3–108).

3–23 LOWER JACKSHAFT REMOVAL 1. Lift side of loader being workedon and remove wheels.

2. Remove clutch caps (Fig. 3–111).

3. Remove side panel (Fig. 3–112).

4. Empty the oil from side reservoir (Fig. 3–113).

tank

PI–01026

Fig. 3–111 Remove Clutch Cap

B–02023

Fig. 3–112 Remove Side Panel

5. Remove linkage from control pedals (Fig. 3–114).

7. Loosen and remove all the drive chains use chain breaker tool (Fig. 3–116).

8. Remove front clutch (Fig. 3–117).

assembly

Drain Plug B–01507

Fig. 3–113 Empty Oil From Tank

C–01781

Fig. 3–114 Remove Pedal Linkage

9. Remove jackshaft holding bolts (Fig. 3–118).

C–01780

Fig. 3–115 Remove Floor Panels

PI–01131

Fig. 3–117 Remove Clutch Assembly 75 of 216

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Dealer Copy -- Not for Resale

6. Remove floor panels (Fig. 3–115).

PI–01181

Fig. 3–116 Using Chain Breaker Tool

PI–01180

Fig. 3–118 Remove Holding Bolts 600, 600D, 610, 611 Loader Service Manual

10. Use tank spreader to spread gear housing (Fig. 3–119).

11. Remove lower jackshaft sprocket from loader by lifting forward and up (Fig. 3–119).

THE IMPRINTED NUMBERS ON THE BEARINGS MUST BE TOWARD THE OUT– SIDE OF THE SPROCKET

3–24 LOWER JACKSHAFT SPROCKET REPAIR 1.

To install bearings in double sprocket: a. Remove old bearings.

PI–01177

b. Install new bearings with numbers to outside of sprocket. Bearing should be seated 1/16’’ (1.9 mm) infrom end of hub. Install a bearing from each end of hub (Fig. 3–120).

Fig. 3–119 Remove Sprocket

PI–01182

Fig. 3–120 Install Bearing Hubs

d. Tighten bolts to 55 ft–lbs. (75 Nm) (Fig. 3–123). e. Install safety 3–123). f.

wire

(Fig.

Inspect shaft for wear and make replacement when necessary (Fig. 3–124).

PI–01178

Fig. 3–121 Liquid Sealant On Bolts

PI–01183

Fig. 3–122 Tightening Sprocket Bolts

g. Install inside thrust washer (Fig. 3–125). h. Install sprocket assembly onto shaft with large sprocket toward plate (Fig. 3–126). i.

Install outside thrust washers (Fig. 3–126).

j.

Install outside holding plate (Fig. 3–127).

3–25 LOWER JACKSHAFT INSTALLATION

PI–01179

Fig. 3–123 Install Safety Wire

PI–01185

Fig. 3–124 Install New Shaft

1. Install jackshaft assembly into gear tank (Fig. 3–119). Use a tank spreader to open tank wider for easier installation.

2. Move sprocket so hole in plate are in line with holes in inner side wall (Fig. 3–119).

3. Install holding bolts through holes in inner side wall.

4. Install final drive chains (Fig. 3–128).

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PI–01186

PI–01187

Fig. 3–125 Install Thrust Washer (Inside)

Fig. 3–126 Install Thrust Washer (Outside)

–3–24–

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

c. Install large sprocket to multiple sprocket. Use a liquid sealant on threads of bolts (Fig. 3–121).

5. Connect chain with press fit connector (Fig. 3–128).

6. Install outside holding bolts (Fig. 3–129). Use heat treated fine thread bolts, with locknuts.

7. Install front clutch assembly (Fig. 3–130).

PI–01188

Fig. 3–127 Install Outside Holding Plate

PI–01189

Fig. 3–128 Install Drive Chain

8. Install secondary drive chain by using wire (Fig. 3–131).

10. Install primary chain.

11. Connect primary chain press fit connector.

with PI–01180

Fig. 3–129 Install Holding Bolts

PI–01131

Fig. 3–130 Install Front Clutch

12. Tighten all chains (See Drive Chain Adjustment page 3–26).

13. Install side panel.

Dealer Copy -- Not for Resale

9. Connect secondary chain with press fit connector (Fig. 132).

14. Install clutch caps.

15. Install floor panels (Fig.3–133).

PI–01190

Fig. 3–131 Install Secondary Chain

PI–01191

Fig. 3–132 Install Chain Connector

16. Connect control pedal linkage (Fig. 3–134).

C–01780

Fig. 3–133 Install Floor Panels 77 of 216

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C–01781

Fig. 3–134 Connecting Control Pedal Linkage 600, 600D, 610, 611 Loader Service Manual

3–26 DRIVE CHAIN ADJUSTMENT a 1. Remove clutch caps.

2. Remove side panels.

3. To make adjustment of drive chains:

final

a. Loosen outside holding bolts for lower jackshaft (Fig. 3–135).

PI–01163

C–01781

Fig. 3–135 Loosening Outside Holding Bolts

Fig. 3–136 RemoveControl Pedal Linkage

b. Remove linkage to control pedals (Fig. 3–136).

d. Loosen inside holding bolts for lower jackshaft (Fig. 3–138). e. Use a pry bar in hole of large sprocket to tighten chain (Fig. 3–139).

C–01780

Fig. 3–137 Remove Floor Pedals f.

PI–01164

Fig. 3–138 Loosen Inside Holding Bolts

Tighten chain to 1/4’’ (6.4 mm) play with 40 pounds (18.1 Kg) of pull (Fig. 3–140).

g. Tighten two outside and two inside holding nuts to 110 ft.–lbs. (149 Nm) (Fig. 3–141).

40 LBS. 1/4’’

h. Put control levers in neutral. Turn wheels to check play (Fig. 3–142).

PI–01192

Fig. 3–139 Tightening Chain

PI–01193

Fig. 3–141 Tightening Holding Nut 78 of 216

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PI–01194

Fig. 3–140 Drive Chain Adjustment

B–02592

Fig. 3–142 Check For Freeplay 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

c. Remove floor panels (Fig. 3–137).

4. Adjustment of secondary chain. a. Loosen two nuts on secondary chain idler (Fig. 3–143). b. Use bar to force down on idler bracket (Fig. 3–144). c. Tighten chain to 1/8’’ (6.4 mm) play with 15 lb. (6.8 kg) pull (Fig. 3–145). d. Tighten idler holding nuts to 110 ft.–lbs. (149 Nm).

PI–01162

e. Put control levers in neutral and turn wheel to check play.

Fig. 3–143 Loosening Secondary Idler

5. Adjustment of primary chain. a. Loosen two nuts holding primary idler (Fig. 3–146).

c. Tighten to 1/8’’ (3.2 mm) play with light hand pressure (Fig. 3–147). d. Tighten two idler holding nuts to 30 ft.–lbs. (41 Nm) (Fig. 3–146).

PI–01141

PI–01195

Fig. 3–144 Secondary Idler Adjustment

Fig. 3–145 Secondary Chain Adjustment

e. Inspect idler sprocket for clearance. f.

Dealer Copy -- Not for Resale

b. Pull idler sprocket forward to tighten chain.

Turn wheels on loader and check play . Inspect for chain clearance of other parts in system.

6. Install side panels.

7. Install clutch caps.

PI–01139

8. Install floor panels.

Fig. 3–146 Loosening Primary Idler

9. Connect control pedal linkage.

10. Start loader, engage control lever and check operation.

11. Inspect for oil leaks.

12. Shut off loader and remove blocks.

PI–01140

Fig. 3–147 Primary Chain Adjustment 79 of 216

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600, 600D, 610, 611 Loader Service Manual

3–27 BRAKE ASSEMBLY 1. Remove safety step.

2. Disconnect control pedal linkage.

3. Remove floor panels.

4. Remove four brake drum bolts (Fig. 3–148).

B–01950

Fig. 3–148 Remove Drum Bolts

Fig. 3–149 Remove Cotter Pin, nut & Washers

5. Remove cotter pin, axle nut and washer (Fig. 3–149).

6. Remove brake shoe holding plate (Fig. 3–150).

3–28 ASSEMBLY OF BRAKE 1. Install axle seal and O–ring (Fig. 3–152).

B–01947

2. Install brake drum holding hub (Fig. 3–151).

Fig. 3–150 Remove Shoe Holding Plate

3. Install brake shoe holding plate (Fig. 3–148).

4. Install washer and axle nut (Fig. 3–149).

5. Tighten castle nut to preload bearing to 65 ft.–lbs. (88 Nm).

6. Install cotter pin.

7. Install brake drum (Fig. 3–153).

C–01808

Fig. 3–151 Remove Drum Holding Hub

Fig. 3–152 Install Seal and O–ring

B–01949

Fig. 3–153 Install Brake Drum 80 of 216

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600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

7. Remove brake drum holding hub (Fig. 3–151).

3–29 BRAKE ADJUSTMENT Adjust To Tighten Brake

1. To make adjustment, turn control levers clockwise (Fig. 3–154).

2. When all adjustment is taken up: a. Disconnect hydraulic control pedal linkage. b. Remove floor panels. c. Loose n locking nut on control linkage. lower clevis

pin (Fig. Lower Clevis

e. Turn control lever counter clockwise until threads are at beginning of adjustment (Fig. 3–154).

Dealer Copy -- Not for Resale

d. Remove adjustment 3–154).

C–01844

f.

Shorten clevis.

Fig. 3–154 Brake Lever and Pedal Linkage

g. Linkage rod adjustment is correct when control handle is tight when engage.

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600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

610,611ServiceManual#6556276–DriveSystemSectionPages3–29

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600, 600D, 610, 611 Loader Service Manual

HYDRAULIC SYSTEM

ASSEMBLY OF HYDRAULIC PUMP (WEBSTER PUMPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–21 ..

ASSEMBLY OF VARIABLE SPEED CONTROL VALVE SEAL REPLACEMENT WITH CONTROL VALVE . . 4–16 CARTRIDGE RELEASE ADJUSTMENT . . . . . . . . . . . . . . . . . .4–9 CHECKING CONDITION OF HYDRAULIC PUMP . . . . . . . . . 4–6 CHECKING PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . .4–12 CHECKING THE CONDITION OF HYDRAULIC SYSTEM . . 4–5 CHECKING THE PRESSURE SETTING OF THE CARTRIDGE RELEASE . . . . . . . . . . . . . . . . . . . . . . . . .4–7 .

CHECKING VARIABLE SPEED VALVE PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .4–10 .

CONTROL VALVE SEAL INSTALLATION . . . . . . . . . . . . . . . .4–17 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20 ...

DISASSEMBLY OF VARIABLE SPEED CONTROL VALVE . 4–15 HYDRAULIC CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . 4–1 .

HYDRAULIC CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . 4–26 .

HYDRAULIC LIFT OR TILT CYLINDER DISASSEMBLY . . . . 4–24 HYDRAULIC PUMP ALIGNMENT (500 ELECTRIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–27 ..

HYDRAULIC PUMP ALIGNMENT (600 WISCONSIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–28 ..

HYDRAULIC PUMP ASSEMBLY (CESSNA PUMP) . . . . . . . . 4–23 HYDRAULIC PUMP DISASSEMBLY (CESSNA PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–22 ..

HYDRAULIC PUMP SERVICE (WEBSTER PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–19 ..

HYDRAULIC SYSTEM (600 ELECTRIC & 600 DIESEL W/PETTER ENGINE) . . . . . . . . . . . . . . . . . . . . 4–4 .

HYDRAULIC SYSTEM (600 & 610 DIESEL W/DEUTZ ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–3 ..

HYDRAULIC SYSTEM (600, 610 GASOLINE & LP GAS) . . . 4–2 INSTALLATION OF CYLINDER SEALS . . . . . . . . . . . . . . . . . .4–25 INSTALLING VALVE SPOOL SEALS IN THE VARIABLE SPEED CONTROL VALVE . . . . . . . . . . . . . . . . . .4–18

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Page Number 4–11 4–7 4–4 4–3 4–6 4–2 4–4 4–5 4–8 4–10 4–7 4–1 4–13 4–13 4–14 4–15 4–12 4–12 4–10

HYDRAULIC SYSTEM

Dealer Copy -- Not for Resale

Paragraph Number

4–2 4–1 4–1 4–13 4–9

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale 84 of 216

–4–0–

600, 600D, 610, 611 Loader Service Manual

HYDRAULIC SYSTEM 4–1 Hydraulic Circuit Operation The loader is equipped with full–flow positive–pressure lubrication to clutches and drive system. Oil is pulled from reservoir through a filter into the pump. The pump forces it through the control valves and clutches, back to reservoir . This is with hydraulic controls in neutral (Fig. 4–1 & 4–2).

When a control is activated, oil is sent into one end of selected cylinders. Oil flows from other end of cylinders back to valve group through the clutches and into reservoir. When the valve is put in neutral, oil is stopped in cylinder, holding the load in place and the oil again moves from pump through valves and clutches and into reservoir. A release valve in the system prevents an overload in the circuit.

Oil is pulled from reservoir through the hydraulic oil filter (Item 1) by hydraulic pump (Item 2), pump moves fluid to control valves (Item 3, 4 & 5). The main release valve (Item 6) is a valve set to open when a control valve is activated and the cylinders hit the end oftheir stroke, or when lifting a load larger than the loader’s capacity. When moving variable speed control lever forward, oil is moved by variable speed control valve (Item 5) to variable speed cylinder (Item 7). This moves the drive sheaves together, giving faster ground speed. Pulling lever back will slow ground speed. A check valve in the clutch lubrication manifold (Item 8) holds a pressure of 20 PSI (138 kPa) to the drive clutches.

B–01156

Fig. 4–1 Hydraulic System (600, 610 Loaders)

Dealer Copy -- Not for Resale

4–2 Hydraulic System (600, 610 Gasoline and LP Gas) Fig. 4–7 Hydraulic Fluid Flow)

4–3 HYDRAULIC SYSTEM (600 and 610 Diesel W/Deutz Engine) (Fig. 4–2 Hydraulic Flow) Oil flows from the reservoir through the hydraulic oil filter (Item 1) by hydraulic pump (Item 2).

Pump moves fluid to control valve (Item 3, 4 & 5). The main release valve (Item 6) is a valve set to open when a control valve is activated and the cylinders hit the end of their stroke, or when lifting a load larger than the loader ’s capacity. When moving variable speed control lever forward, oil is moved by variable speed control valve (Item 5) to variable speed cylinder (Item 7). This moves the drive sheaves together, giving faster ground speed. Pulling lever back will slow ground speed. A check valve in the clutch lubrication manifold (Item 8) holds the pressure of 20 PSI (138 kPa) to the drive clutches.

B–01157

Fig. 4–2 Hydraulic System (600, 610 Deutz) 85 of 216

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600, 600D, 610, 611 Loader Service Manual

4–4 HYDRAULIC SYSTEM (600 Electric and 600 Diesel W/Petter Engine) ( Fig. 4–3 Hydraulic Flow) Oil is pulled from the reservoir , through the hydraulic oil filter by hydraulic pump. Pump moves fluid to control valve. The main releasevalve is a valve set to open when a control valve is activated and the cylinders hit the end of their stroke, or when lifting a load larger than the loader ’s capacity. When moving variable speed control lever forward, oil is moved by variable speed control valve to variable speed cylinder. This moves the drive sheaves together, giving faster ground speed. Pulling lever back will slow ground speed. A check valve in the clutch lubrication manifold holds a pressure of 20 PSI (138 kPa) to the drive clutches.

Lift all four wheels of the loader off the floor. Put blocks under the flame to support it before starting check.

W–2316–0498

4–4a RESTRICTOR FOR TILT HYDRAULIC CIRCUIT (Grapple Operation Only)

B–01158

Fig. 4–3 Hydraulic System (600 Peter)

This restrictor is installed to slow the flow of hydraulic oil through the tilt cylinders when tilting the Bob–T ach forward. Install as shown in (Fig. 4–4a).

4–5 CHECKING THE CONDITION OF HYDRAULIC SYSTEM The hydraulic tester must be used to check pump output, release setting, cylinder seals and control valve condition.

1. Connect tester to the auxiliary hydraulic tubelines at rear of loader (Fig. 4–4). a. Connect a hose from rear auxiliary tubelines to outlet opening of tester (Item 1). b. Connect a hose from front tubeline to inlet opening of tester (Item 2).

2. Start the engine.

3. Operate at full throttle.

4. Hold down front of auxiliary control pedal (Item 3).

5. Turn pressure control valve on tester at a slow rate.

6. Check flow reading on tester.

7. Flow reading must be evenuntil master relief valve opens.

When valve opens, flow ratewill drop suddenly.

86 of Revised Feb. 80216

A–01107

Fig. 4–4 Testing Hydraulic System –4–2–

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

WARNING

8. See chart below for volume of oil a new pump will move until master relief valve opens.

RECOMMENDED HYDRAULIC OIL FLOW RATE 600 (Gasoline or LP Gas) . . . . . . . . 10 gal/min (38L) 610 . . . . . . . . . . . . .11 gal/min (42L) 600 (Diesel) Deutz . . . . . 10 to 11 gal/min (42L) Petter 10 ga/min (38L) at 300 RPM 600 (Electric) . . . 8 gal/min (30L) at 1750 RPM 9. An old pump will show a lower reading.

10. Close pressure control valve.

Pressure should be between 1700–1750 PSI (11720–12066 Fig. 4–4a Restrictor kPa).

4–6 CHECKING CONDITION OF HYDRAULIC PUMP (Fig. 4–5)

B–1661R

1. Remove the hoses from the auxiliary tubeline.

Dealer Copy -- Not for Resale

2. Connect hoses to tilt cylinder tubelines at the rear of loader. a. Connect hoses from inlet opening of tester to rear tilt tubeline (Item 1). b. Connect hose from outlet opening of tester to front tilt tubeline (Item 2).

3. Place a stop (5/16 by 1’’ [7,9 mm by 25,4 mm] long carriage bolt) between clutch lubrication manifold tee and master release valve tubeline fitting (Item 3).

1

4. Open pressure control.

5. Start the engine and run at low idle.

6. Hold back of tilt control down (Item 4).

pedal

2

7. Slowly turn the pressure control on tester clockwise to increase the system pressure.

IMPORTANT

Tilt Lines

When this method is used there is no relief valve in the system. Closing the pressure control rapidly will cause over maximum pump pressure and can damage the pump or tester. Do not increase the pressure over 2000 PSI (13790 kPa).

3

4

I–2175–0598

8. When reading of pump pressure is above 1850 PSI (17755 kPa) pump is good. Refer to flow chart above.

87 of 216 Revised Feb. 80

Tilt Pedal

A–01108

Fig. 4–5 Testing Hydraulic System –4–3–

600, 600D, 610, 611 Loader Service Manual

4–7 CHECKING THE PRESSURE SETTING OF THE CARTRIDGE RELEASE (In Lift and Auxiliary Control Valve)

1

1. Connect tester to auxiliary tubelines at rear of loader (Fig. 4–6).

2

a. Connect a hose from the rear auxiliary line to outlet opening of tester (Item 1). b. Connect a hose from front auxiliary line to inlet opening of tester (Item 2).

3 Aux. Lines

2. Leave the stop (5/16 x 1’’ [7,9 mm x 25,4 mm] long carriage bolt) between the clutch lubrication manifold tee and master release valve tubeline (Item 3).

4

3. Open pressure control on tester.

5. Hold front of auxiliary pedal down (Item 4).

Dealer Copy -- Not for Resale

4. Start the engine and run at 1/4 throttle. control Auxiliary Pedal

6. Turn the pressure control on the tester until cartridge release valve Fig. 4–6 Checking Lift and Auxiliary Release Pressure opens. the pressure setting of this cartridge release should be 1800+100 or –100 PSI (12411±690 kPa).

WARNING

Do not forget to remove the stop (carriage bolt) from between the clutch lubrication manifold tee and the master release valve tubeline.

4–8 MASTER RELEASE VALVE ADJUSTMENT 1. Remove hex cap from valve body (Fig. 4–7).

2. Remove spring and shim from behind it (Fig. 4–7).

3. Adding a shim will increase system pressure and installing a thin shim for thick shim will decrease pressure. Adding a .010 (2,5 mm) inch thick shim will increase pressure approximately 100 PSI (690 kPa).

Fig. 4–7 Release Valve Adjustment

4. Install cap and check pressure. Make further adjustments when needed.

4–9 CARTRIDGE RELEASE ADJUSTMENT 1. Remove hex cap from front of valve (Fig. 4–8).

2. Remove shim from behind it.

Shim

3. Adding a shim will increase pressure. Installing a thin shim for a thick shim will decrease pressure.

4. Install cap and check pressure. Make further adjustments when needed.

Cap C–01051

Fig. 4–8 Remove Hex Cap 88 of 216

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600, 600D, 610, 611 Loader Service Manual

WARNING Variable speed closing pressure must not be over maximum on variable speed internal roto–swivel (See below). It must never be above the pressure necessary to shift from full low speed to full high speed position in four seconds at full engine RPM. W–2318–0598

4–10 CHECKING VARIABLE SPEED VALVE PRESSURE ADJUSTMENT (Variable Speed Swivel Couplings)

4–11 Variable Speed Control V alve With Holding Pressure Release Valve

C–01765

Dealer Copy -- Not for Resale

When making adjustment and checking variable speed closing and holding pressure, it is important first to note which type of swivel coupling is used.

The internal roto–swivel type needs a higher closing and holding pressure to operate properly. (See warning note above.)

C–01760

Fig. 4–9 Adjust Variable Speed Valve

The variable speed sheave must close in the drive sheave in four seconds at full engine RPM. When belt comes up faster than four seconds, decrease closing pressure. When belt comes up slower than four seconds, increase the closing pressure. This adjustment is made by turning pressure release valve adjustment in or out (Fig. 4–12). When making this adjustment, do not go over 550 PSI (3792 kPa) pressure. Inspect tension on holding release spring. Plunger must not move in valve body when belt is in high variable speed position with full engine RPM (Fig. 4–10).

1. Install a 1000 PSI (7000 kPa) pressure gauge into the rear opening of variable speed control valve (Fig. 4–9).

2. Start the engine and run at full throttle.

3. Move the variable speed control lever forward to high speed position (Fig. 4–9). Hold it there.

C–01760

Fig. 4–10 Variable Speed Valve Spring

4. The indicator on the gauge should show closing pressure of 350–550 PSI (2400–3800 kPa) 5. Return the lever to neutral.

6. Check holding release valve pressure.

7. Twist the hose to increase pressure to holding release valve. Check pressure increase for maximum reading.

8. The reading should be 750–775 PSI (5170–5340 kPa).

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4–12 CHECKING PRESSURE ADJUSTMENT (Variable Speed Control Valve with no Holding Pressure Valve ) (Fig. 4–11) Using this type valve, oil is moved into variable speed cylinder at a variable speed closing pressure of 375–400 PSI (2585–2758 kPa) or 475–500 PSI (3275–3447 kPa) on variable speed with rotor–swivel inside. Check the variable speed closing pressure using same method as when checking the variable speed valve with holding pressure release (Steps 1 through 5).

4–13 VARIABLE SPEED CLOSING PRESSURE ADJUSTMENT (V ariable Speed Control Valve with or with no Holding Release V alve) (Fig. 4–12) 1. To increase the closing pressure, turn the set screw plug into the valve a little at a time (Item 1).

3. If plug becomes overtight while increasing the pressure, a shim can be added between the set screw plug and spring (Fig. 4–13).

4. To lower the closing pressure, loosen the set screw plug until the pressure is 400 PSI (2758 kPa) or 475–500 PSI (3275–3447 kPa) on variable sheave with roto–swivel inside.

C–01053

Fig. 4–11 Variable Speed Valve

B–02413

Fig. 4–12 Adjust Closing Pressure

5. If the plug becomes loose, causing an oil leak, shorten the spring by grinding off the end of it.

Do not overheat the spring when grinding.

4–14 VARIABLE SPEED HOLDING RELEASE PRESSURE SETTING (Fig. 4–12) (600 PSI [4137 kPa] Minimum)

C–01053

Fig. 4–13 Add Shims To Jet Screw Plug

1. To increase pressure setting, turn hexagon nut in spring holding bracket so it moves toward spring. Turn nut 1/4 rotation then check pressure setting.

2. If nut runs out of threads, put a washer between nut and spring.

3. To decrease pressure setting, turn hexagon nut so that it moves away from spring.

NOTE: A loader used under heavy loads, may require more than 600 PSI (4137 kPa) holding pressure to prevent variable speed leak down and O–ring damage in holding pressure nut. On loaders equipped with variable speed, having roto–swivel inside, holding pressure should be 700 PSI (4826 kPa).

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Dealer Copy -- Not for Resale

2. Turn the plug into maximum pressure of 400 PSI on loaders with variable speed sheave with outside roto–swivel (2758 kPa) turn plug into maximum pressure of 475–500 PSI (3275–3447 kPa) on variable sheave with roto swivel inside.

4–15 DISASSEMBLY OF VARIABLE SPEED CONTROL V ALVE (Seal Replacement with Control Valve in the Bobcat) 1. Remove seat and seat plate (Fig. 4–14).

2. Remove variable speed control lever linkage rod.

3. Remove temperature release valve bracket (Fig. 4–15, Item 1).

4. Remove push rod guide and push rod (Fig. 4–15, Item 2).

C–01784

Fig. 4–16 Remove Seat and Plate

5. Use magnet to remove ball and spring (Fig. 4–15, Item 3).

6. Remove end cap and spring (Fig. 4–15, Item 4).

5 1

7. Install seal on dust cap end of spool (Fig. 4–15, Item 5).

4

9. Move spool forward to install new seal on clevis end of spool (Fig. 4–17).

Ball & Spring

3

Dealer Copy -- Not for Resale

8. Move spool back to install new back seal (Fig. 4–18).

Guide

2

Push Rod

C–01053

Fig. 4–15 Variable Speed Valve Parts

NOTE: Do not push spool beyond its limits asthis can cause seal to go into groove of valve and result in damage to seal.

10. Move spool back into normal position.

4–16 ASSEMBLY OF VARIABLE SPEED CONTROL V ALVE, SEAL REPLACEMENT WITH CONTROL V ALVE IN THE BOBCAT (With Holding Release Valve) (Fig. 4–15) 1. Install spring assembly and end cap (Item 4) PI–01199

2. Install new seals on push rod and push rod guide (Item 2)

Fig. 4–16 Install Back Seal

3. Place ball on small round end of spring (Item 3). (Use grease to hold spring and ball to end of rod guide.)

4. Install push rod and rod guide (Item 2).

5. Install push rod bracket (Item 1).

6. Connect variable speed control linkage.

7. Make pressure adjustments. (See Paragraph 4–13 and 4–14).

PI–01201

Fig. 4–17 Install Front Seal 91 of 216

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600, 600D, 610, 611 Loader Service Manual

4–17 CONTROL V ALVE SEAL INSTALLATION (Fig. 4–18, 4–19) (For Tilt, Lift Valve and Auxiliary Cylinder Control Valve)

1

2

3 4

1. Remove rubber cap from back of valve (Item 1).

2. Remove large snap ring and stop disc (Item 2 & 3).

3. Remove spring assembly bolt.

Centering spring lock washer , stop collar, spring and stop washer (Item 4)

C–01240

Fig. 4–18 Lift and Auxiliary Valve Parts

4. Push spool into housing from front of valve until front seal is out, then remove front seal (Fig. 4–20).

1

2

3 4 5

6. Clean both seal grooves.

7. Install spool, through front of housing with spring fastening end of spool first (Fig. 4–19, Item 5).

8. Push spool into valve until end of spool is at back seal groove.

C–01049

Fig. 4–19 Tilt Valve Parts 9. Install a new seal in back groove. Place U cup of seal toward valve body (Fig. 4–22).

10. Inspect seal for smooth fit.

11. Push spool into housing from front until front groove can be seen.

NOTE: Do not push spool back more than necessary or back seal will be damaged.

12. Install a new front seal, keep the U cup side of the seal toward valve body (Fig. 4–23).

13. Inspect seal for smooth fit.

PI–01197

14. Push spool through the housing until 1/4 inch of spool surface is shown at front of valve.

Fig. 4–20 Removing Front Seal

15. Install spring assembly bolt, spring, lock washer , stop collar, spring and lock washer (Fig. 4–18, 4–19).

16. Tighten assembly bolt.

17. Install stop disc and snap ring (Fig. 4–18, 4–19, Item 2 & 3).

18. Install rubber cap (Fig. 4–18, 4–19, Item 1).

PI–01198

Fig. 4–21 Removing Spool 92 of 216

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PI–01199

Fig. 4–17 Install Back Seal 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

5. Pull spool out of housing from front of valve and remove back seal (Fig. 4–21).

4–18 INSTALLING VALVE SPOOL SEALS IN THE V ARIABLE SPEED CONTROL VALVE

4

2

6

1. Remove four bolts from valve spring cap (Fig. 4–23, Item 1).

1

2. Remove screw, lock washer, flat washer, spring and stop collar from end of spool (Fig. 4–23, Items 2, 3, 4, 5 & 6).

3

5

C–01053

Fig. 4–23 Variable Speed Valve Parts 3. Pull valve spool out of housing (Fig. 4–24).

4. Check position of U cup of seals for correct installation of new seals.

5. Remove worn seal (Fig. 4–24).

Dealer Copy -- Not for Resale

6. Install spool in housing with no seals. Push spool into housing until seal groove can be seen at cap end of valve.

7. Install a new seal into back groove (Fig. 4–25).

PI–01204

8. Push seal into housing and pull spool into valve housing (Fig. 4–25).

Fig. 4–24 Remove Valve Spool

9. Pull valve spool toward control end of valve until front seal groove is visual.

10. Install a new front seal (Fig. 4–26).

11. Push seal into housing and spool into place (Fig 4–26).

12. Install collar, spring, washers and screw. Tighten screw (Fig. 4–23, Items 2, 3, 4, 5 & 6).

PI–01205

13. Check that washer moves free on spool.

Fig. 4–25 Install Seal On Valve Spool

14. Install cap and four bolts (Fig. 4–23, Item 1).

15. Check cap for proper alignment. It must be correctly centered over end of spool.

PI–01206

Fig. 4–26 Install Front Seal 93 of 216

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600, 600D, 610, 611 Loader Service Manual

a–19 HYDRAULIC PUMP SERVICE 4 (Webster Pump) For seal replacement in hydraulic pump, follow the below procedure (Fig. 4–27).

1

3 2

5 6

8 7

4–20 DISASSEMBLY

9 11 12

1. Clean outside of pump.

2. Make mark on edges of cover so it can be installed again in same position.

4 10

3. Remove the pilot plate andseal (Fig. 4–28).

C–01042

Fig. 4–27 Hydraulic Pump Breakdown (Webster)

Dealer Copy -- Not for Resale

4. Pull the pump drive shaft out of pump (Fig. 4–29). The ball bearing will come with it.

5. Remove all bolts from pump body (Fig. 4–30).

6. Install two bolts into shaft side and turn them in several turns by hand. Hit sharply on headsof two screws, first one, then the other, then first one again (Fig. 4–31). When the dowels are loose, remove the screws and separate the plates.

7. Inspect the gears, shafts and bearings.

PI–01207

Fig. 4–28 Remove Pilot Plate and Seal

PI–01210

Fig. 4–29 Remove Drive Shaft

8. When needle bearings are bad remove and install new needle bearings (Fig. 4–32).

9. When cover and body plates are worn, grind them smooth.

10. Install new gears after grinding cover and body.

PI–01211

Fig. 4–30 Remove Body Bolts 94 of 216

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PI–01212

Fig. 4–31 Separating Pump Plates 600, 600D, 610, 611 Loader Service Manual

4–21 ASSEMBLY OF HYDRAULIC PUMP (Webster Pump) 1. Wash off pump parts and dry with air.

LETTERED SIDE UP

1/16’’

2. Install ball bearings to pump drive shaft.

3. Install drive shaft into the body (Fig. 4–29).

PI–01214

4. Make seal replacement in pilot plate (Fig. 4–33).

Fig. 4–32 Install New Bearings

Fig. 4–33 Replace Seal In Pilot Plate

5. Set pump body with machined face up (Fig. 4–34).

7. Install idler gear and shaft assembly (Fig. 4–35).

8. Install gear plate over gears and put scratch marks in a line.

PI–01215

Fig. 4–34 Machined Faced Of Pump

PI–01216

Fig. 4–35 Install Idler Gears

9. Install dowel pins through large holes in gear plate (Fig. 4–36).

10. Install cover plate over shaft.

Install and tighten the cover bolts, then turn pump over and install and tighten body bolts (Fig. 4–37).

11. Install pilot plate and fasten with machine screws.

PI–01217

Fig. 4–36 Install Dowel Pins

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Dealer Copy -- Not for Resale

6. Install key in drive shaft and lower drive gear over it (Fig. 4–34).

A–01076

Fig. 4–37 Install Body Bolts

600, 600D, 610, 611 Loader Service Manual

4–22 HYDRAULIC PUMP DISASSEMBLY (Cessna Pump)

10

1. Remove key from pump drive shaft (Fig. 4–38).

1

4

5

2. Clean outside of pump. Put marks in a line across edges of cover , gear plate and body (Fig. 4–39).

3. Hold pump in a vise shaft down.

Remove bolt which holds the pump plates together (Fig. 4–41).

4. Remove pump from vise.

Separate pump plates by hitting shaft onto a wooden block (Fig. 4–40).

10

9

3 2

6

9

C–01090

Fig. 4–38 Hydraulic Pump Breakdown (Cessna)

5. Remove these items (Fig. 4–38) from front plate of pump. a. Diaphragm (Item 1) b. Springs (2)* Steel Balls (2) (Item 2 & 3) c. Gaskets (2) (Item 4) d. Molded V Seal (Item 5) e. Shaft Seal (Item 6)

7. Inspect pump drive shaft for a broken key way. Inspect pump drive shaft and idler gear shaft at bearing points and seal areas. When shaft diameter measures less than .6850 inch (17,5 mm) is in the bearing area, make replacement.

8. Inspect the gear faces for wear. Check with following chart: If gear width is below these figures, replace the gears. a. Pump Model B24387–OBAA .636 inch (16,3 mm) b. Pump Model 15509–OEBA .636 inch (16,3 mm) c. Pump Model 15510–OEBA .767 inch (19,6 mm)

A–01008

Fig. 4–39 Marking Pump Sections

9. Inspect the back plate for wear. When worn more than .0015 inch (,038 mm) install new plate.

10. Check inside diameter of bearings in place. When inside diameter is worn more than .691 inch (17,5 mm) install new plates.

11. Inspect chambers in gear plates for wear. When chamber is worn, more than 1.719 inches (43,6 mm) install new gear plate.

4–23 HYDRAULIC PUMP ASSEMBLY (Cessna Pump) 1. When assembling install new parts as follows: (Fig. 3–28). a. Diaphragm (Item 1) b. Gaskets (2) (Item 4) c. V Seat (Item 5) d. Shaft Seal (Item 6)

PI–01218

Fig. 4–40 Holding Pump In Vise

2. Install V seal into groove in front plate. Install seal with open part of V toward plate (Item 5).

3. Put gasket into V seal (Item 4).

4. Drop steel balls into seat and place springs over balls (Item 2 & 3).

5. Place diaphragm over gasket, bronze face up (Item 1).

6. Make sure diaphragm fits inside raised edge of V seal.

7. Put oil on gears and slide them into front plate bearings.

8. Put grease on both faces of gear plates and install plates over gears (Item 9 & 10).

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PI–01219

Fig. 4–41 Separating Pump Parts 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

6. Clean and dry all pump parts.

9. Check marks on side of plates when installing, to be sure they are in alignment (Fig. 4–39).

10. Slide backplate over gear shaft until dowel pins are engaged.

11. Install bolts and tighten them evenly to 25 ft.–lbs. (34 Nm) (Fig. 4–40).

12. Install pump drive shaft seal over shaft being careful not to cut rubber sealing edge.

13. Seat seal with a hammer.

plastic

4–24 HYDRAULIC LIFT OR TIL T CYLINDER DISASSEMBLY

B–02587

Fig. 4–42 Remove Lift Cylinder

1. Remove hydraulic cylinder from loader (Fig. 4–42).

2. With spanner wrench, remove head from cylinder (Fig. 4–43).

4–25 INSTALLATION CYLINDER SEALS

OF A–01896

1. File and grind a bevel on shoulder at piston end cylinder shaft (Fig. 4–45).

of

2. Remove all rough areas of shaft (Fig. 4–46).

f

B–02583

Fig. 4–43 Remove Cylinder Head

Fig. 4–44 Remove Cylinder Shaft W/Piston

3. Put teflon piston seals in warm oil or water for several minutes before installing.

4–26 HYDRAULIC CYLINDER ASSEMBLY (Fig. 4–47) 1. Install cylinder head seals and place cylinder head carefully onto cylinder shaft (Item 1 thru 6).

2. Install bushing onto shaft (lift cylinder only) (Item 7).

PI–01221a

PI–01221b

Fig. 4–45 Filing Bevel On Shaft

Fig. 4–46 Remove Marks on Shaft

3. Install piston seals and place piston onto end of cylinder shaft (Items 8, 9 & 10).

4. Install piston locking nut and tighten it (Item 11).

9 11

5. Install piston and shaft into cylinder.

Dealer Copy -- Not for Resale

3. Pull shaft and piston assembly from cylinder housing (Fig. 4–44).

10

8

7

3

2

1

6. Install cylinder head into cylinder case. Be careful not to damage seals.

7. Tighten cylinder head with spanner wrench (Fig. 4–43).

4 5 6

C–01052

Fig. 4–47 Hydraulic Cylinder Assembly 97 of 216

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600, 600D, 610, 611 Loader Service Manual

4–27 HYDRAULIC PUMP ALIGNMENT (500 ELECTRIC) 1. Remove hydraulic pump and pump holding plate from motor housing (Fig. 4–48).

2. Remove two pump holding bolts.

3. Install bolt with lock washers and put nuts on pump side. Tighten nuts and spot weld them to plate (Fig. 4–49).

4. Remove pump from holding plate.

5. With center punch mark 8 drill holes. They should be positioned 2 per every 90° around the bell housing so set screws will seat against four machined bosses on motor housing (Fig. 4–50).

6. Remove bell housing from motor (Fig. 4–50).

PI–01229

Fig. 4–48 Removing Pump and Plate

7. Drill 8 holes and turn a 1/4 inch (6,4 mm) by 20 tap through them (Fig. 4–50).

9. Remove worn pump drive adapter from motor shaft (Fig. 4–51).

10. Attach bell housing to motor and tighten holding bolts evenly (Fig. 4–52).

11. Install pump holding plate to housing (Fig. 4–53).

PI–01231

Fig. 4–49 Spot Weld Nuts

PI–01230

Fig. 4–50 Drilling & Tapping Housing

12. Install a new pump drive adapter into end of motor shaft. Hit bolt lightly with hammer and tighten.

13. Fasten a dial indicator to shaft so that indicator arm slides on inner circumference of holding plate for pump (Fig. 4–54).

14. Using a long bar , force variable speed drive belt into driven sheave. This will loosen belt in drive sheave so motor shaft may be turned by hand.

15. Turn motor shaft by hand noting dial indicator reading.

Make adjustment of 8 set screws to move bell housing until a maximum total indicator reading of .004 inch (,102 mm) is made.

PI–01232

Fig. 4–51 Remove Old Adaptor

PI–01233

Fig. 4–52 Install Bell Housing

16. Tighten housing holding bolts (Fig. 4–53).

17. Remove dial indicator.

18. Install hydraulic pump on holding plate (Fig. 4–48).

PI–01234

Fig. 4–53 Install Holding Plate 98 of 216

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PI–01235

Fig. 4–54 Using Dial Indicator 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

8. Start 1/4 inch (6,4 mm) set screws in holes.

4–28 HYDRAULIC PUMP ALIGNMENT (600 Wisconsin)

Alignment Tool

NOTE: Use pump alignment tool.

(See parts book for correct tool).

1. Remove pump and drive coupling from engine (Fig. 4–60).

2. Slip tool over pump shaft tobottom position (Fig. 4–55).

3. Place pump into holding bracket and hold it in position (Fig. 4–56).

C–01809

Fig. 4–55 Install Alignment Tool

B–02564

Fig. 4–56 Install Pump and Tool

4. Slide tool over accessory drive shaft (Fig. 4–56).

5. To make correct alignment do the following:

b. With bracket installed loosely shim between bracket and engine block, or grind off block to make alignment. Tighten bolts (Fig. 4–57).

B–02567

Fig. 4–57 Shimming Holding Bracket 6. With brackets fastened and pump fastened in place, check alignment between pump and drive shaft from distributor (Fig. 4–58). Add or remove shims or grind away block on engine with alignment is correct.

C–01809

Fig. 4–58 Check Shaft Alignment

7. Remove pump tool and install drive coupling half loosely to accessory drive shaft.

8. Install other half coupling loose on pump (do not install rubber), and push pump into bracket. Install and tighten pump fastening bolts.

9. Pull each coupling half together on drive and pump shaft. Check for .025 inch (,63 mm) clearance between each half of coupling. use feelers gauge and check all the way around coupling while not turning shaft (Fig. 4–59).

Dealer Copy -- Not for Resale

a. Loosen holding bolts for pump bracket and move bracket up or down or rotate on accessories shaft.

B–02421

Fig. 4–59 Using Feeler Gauge

10. When alignment is correct, remove pump and tighten set screws in drive hub evenly to 9 ft.–lbs. (14 Nm) (Fig. 4–60).

11. Install pump into bracket and hold with fasteners and bolts (Fig. 4–60).

12. Check again for .025 inch (,63 mm) clearance between each coupling half (Fig. 4–59).

E–01089 B–01230

Fig. 4–60 Pump Installation 99 of 216

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600, 600D, 610, 611 Loader Service Manual

4–29 37° Flare Connections 610,611ServiceManual#6556276–HydraulicSystemSection

Use the following procedure to tighten flare fittings: (1) Tighten the nut until it makes contact with the seat.

Mark a Line on Nut Flats of Both Nuts

(2) Make a line across theflats of both the male and female parts of the connection (Fig. 4–61).

(3) Use chart below to find correct tightness needed.

Fitting Thread Size

Rotate No. Of Hex Flats

9/16–18

2

3/4–16

2

7/8–14

1–1/2–2

1–1/16–12

1

1–5/16–12

3/4–1

Tighten to Correct Amount from Chart

A–01897

Fig. 4–61 Tightening Flared Fittings

Make replacement of tubelines that have damage. A bent tubeline will cause oil to flow at a slow rate and will cause an increase in heat and a decrease in hydraulic action. Make replacement of hoses when wear ordamage is present. Use correct clamps to hold tubelines and hoses in position.

Dealer Copy -- Not for Resale

4–30 Tubelines and Hoses O–ring

4–31 Installing O–Rings When installing this fitting, lubricate the O–ring with oil. Loosen the jam nut, screw the fitting into place and connect the tubeline first, before tightening the jam nut.

Tighten the jam nut until it and the washer are tight against the face of the opening (Fig. 4–62). The O–ring must be pushed into the space shown.

O–ring A–01852

Fig. 4–62 Straight Thread Seal

100 of 216

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600, 600D, 610, 611 Loader Service Manual

WISCONSIN ENGINE SERVICE

101 of 216

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WISCONSIN ENGINE SERVICE

Dealer Copy -- Not for Resale

Paragraph Page Number Number ASSEMBLY OF VAPORIZER . . . . . . . . . . . . . . . . . . . . . . . . . .5–21 .

5–9 ASSEMBLY FUEL BOWL AND INTAKE ASSEMBLY . . . . . . . 5–9 5–3 ASSEMBLY THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . .5–10 .

5–4 ASSEMBLE VAPORIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20 ..

5–8 ASSEMBLY OF ENGINE AFTER RECONDITIONING INSTALLATION OF VALVE TAPPETS . . . . . . . . . . . . . . . . . .5–42 5–14 ASSEMBLY OF FUEL BOWL AND THROTTLE BODY . . . . . 5–11 5–4 CARBURETOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . .5–5 .

5–2 CARBURETOR RECONDITIONING . . . . . . . . . . . . . . . . . . . . 5–6 .

5–2 DISASSEMBLE THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . 5–7 .

5–2 DISASSEMBLING VAPORIZER . . . . . . . . . . . . . . . . . . . . . . . .5–19 .

5–8 DISASSEMBLY OF THE FUEL BOWL . . . . . . . . . . . . . . . . . . 5–8 .

5–3 ENGINE RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . .5–24 .

5–11 FUEL FILTER LOCK–OFF DISASSEMBLY . . . . . . . . . . . . . . .5–23 5–10 GOVERNOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .5–2 .

5–1 INSTALLATION OF ACCESSORIES . . . . . . . . . . . . . . . . . . . . 5–58 .

5–18 INSTALLATION OF AIR HOUSING . . . . . . . . . . . . . . . . . . . . . 5–56 .

5–18 INSTALLATION OF CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . .5–43 .

5–14 INSTALLATION OF CAMSHAFT GEAR . . . . . . . . . . . . . . . . . .5–52 5–17 INSTALLATION OF CARBURETOR & MANIFOLD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–55 ..

5–18 INSTALLATION OF CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . 5–44 .

5–15 INSTALLATION OF CYLINDER BLOCKS . . . . . . . . . . . . . . . .5–46 5–15 INSTALLATION OF CYLINDER HEAD . . . . . . . . . . . . . . . . . . 5–54 .

5–17 INSTALLATION OF FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . .5–57 .

5–18 INSTALLATION OF GEAR COVER . . . . . . . . . . . . . . . . . . . . . 5–53 .

5–17 INSTALLATION OF IDLER GEAR & SHAFT . . . . . . . . . . . . . .5–51 5–17 INSTALLATION OF OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . .5–49 .

5–16 INSTALLATION OF PISTON RINGS . . . . . . . . . . . . . . . . . . . . 5–47 .

5–15 INSTALLATION OF PISTONS & CONNECTING RODS . . . . 5–48 5–16 INSTALLATION OF VALVES & SEAT INSERTS . . . . . . . . . . . 5–45 5–15 LP CARBURETOR ASSEMBLING . . . . . . . . . . . . . . . . . . . . . .5–17 .

5–6 LP CARBURETOR CLEANING AND INSPECTION . . . . . . . . 5–16 5–6 LP CARBURETOR DISASSEMBLY PROCEDURE . . . . . . . . 5–15 5–5 LP CARBURETOR RECONDITIONING . . . . . . . . . . . . . . . . . .5–14 5–5 LP CARBURETOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .5–13 .

5–5 LP CARBURETOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . .5–12 .

5–5 LP FUEL FILTER LOCK–OFF . . . . . . . . . . . . . . . . . . . . . . . . .5–22 .

5–10 OIL PAN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–50 ..

5–16 REMOVAL OF ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . .5–26 .

5–11 REMOVAL OF AIR HOUSING . . . . . . . . . . . . . . . . . . . . . . . . .5–28 .

5–11 REMOVAL OF CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 5–32, ..

5–12 5–40 5–14

600, 600D, 610, 611 Loader Service Manual

Paragraph Page Number Number REMOVAL OF CARBURETOR & MANIFOLD . . . . . . . . . . . . .5–29 5–12 REMOVAL OF CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . .5–39 .

5–14 REMOVAL OF CYLINDER BLOCKS . . . . . . . . . . . . . . . . . . . . 5–38 .

5–14 REMOVAL OF CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . .5–30 .

5–12 REMOVAL OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–25 ..

5–11 REMOVAL OF FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–27 ..

5–11 REMOVAL OF GEAR COVER . . . . . . . . . . . . . . . . . . . . . . . . .5–31 .

5–12 REMOVAL OF IDLER GEAR & SHAFT . . . . . . . . . . . . . . . . . .5–33 5–12 REMOVAL OF OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–34 ..

5–12 REMOVAL OF OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–35 ..

5–12 REMOVAL OF PISTONS & CONNECTING RODS . . . . . . . . . 5–36 5–13 REMOVAL OF VALVE TAPPETS . . . . . . . . . . . . . . . . . . . . . . .5–41 .

5–14 REMOVAL OF VALVES & SEAT INSERTS . . . . . . . . . . . . . . .5–37 5–13 RETURN OF NORMAL COMPRESSION . . . . . . . . . . . . . . . . .5–1 5–1 RETURN STORED ENGINE TO SERVICE . . . . . . . . . . . . . . .5–4 5–2 STORAGE OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 ..

5–2 VAPORIZER & PRIMARY REGULATOR SERVICE . . . . . . . . 5–18 5–8

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600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

WISCONSIN ENGINE SERVICE (Cont’d)

5 WISCONSIN ENGINE SERVICE 5–1 RETURN OF COMPRESSION

NORMAL

On a new engine or on one which has been out of operation for some time, the oil may have run off cylinder walls so that compression will be low. Loss of compression will cause hard starting. To correct, remove spark plugs and add about a fluid ounce (.03 kg) of engine oil through the spark plug hole into each cylinder.

Turn the engine over several times by hand for distribution of oil over the cylinder walls. Then install spark plugs and compression should be correct.

The control rod between the governor and carburetor must have proper adjustment length, or governor will not operate correctly .

With engine stopped, the governor spring will hold the fly weight in, and the control rod must be of such length as to hold the carburetor throttle wide open. The adjustments can be checked by disconnecting the control rod from the governor lever, and pushing the rod toward the carburetor as far as it will go. This will open the throttle. The governor lever must then be moved as far as possible in the same direction. All of this is done with the rod disconnected from the lever while holding both parts in above position (Fig. 5–1). the rod must be turned into the swivel block on the carburetor, until the bent end of the rod is in line with the hole in the lever. Then turn rod in two more turns. Install rod into hole ingovernor lever and install the cotter pin (Fig. 5–2). With the governor lever pushed toward the carburetor as far as it will go, there must be about 1/16 of an inch (1,5 mm) clearance between the throttle lever and the stop pin on the carburetor (Fig. 5–3). The clearance will cause the lever to bounce back from stop pin, rather than stop against pin, when a load is appliedto idling engine.

The governor lever has12 holes (Fig. 5–4) for fastening governor spring.

For correct operation, the spring must be fastened to number 10 hole in the arm. This would set engine speed to 2400 RPM under load.

B–02575

Fig. 5–1 Governor Adjustment

Cotter Pin

Dealer Copy -- Not for Resale

5–2 GOVERNOR ADJUSTMENT

B–02601

Fig. 5–2 Governor Lever Installation

12 10 8 6

1/16’’ Clearance

4

Stop Pin

2

B–02605

Fig. 5–3 Stop Pin Clearance 103 of 216

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A–01833

Fig. 5–4 Governor Lever 600, 600D, 610, 611 Loader Service Manual

5–3 STORAGE OF ENGINE

Oil Drain Plug

Clean the outside of engine thoroughly.

To protect the cylinders, pistons, rings and valves from rust, a half and half mixture of kerosene and engine oil should be put into pipe tap opening on intake manifold (Fig. 5–5), while engine is warm and running at low speed.

About 1/4 pint is (,4 ltr .) needed, or enough to cause heavy blue smoke to appear at the exhaust. Then shut off the engine. This operation will cover the above parts with a layer of oil to protect them from corrosion.

B–02599

Fuel Drain

B–02597

Fig. 5–5 Adding Oil Mixture

B–02608

Fig. 5–6 Draining System

Remove oil from oil pan and empty the fuel system (Fig. 5–6).

Idle Discharge Holes

5–4 RETURN STORED ENGINE TO SERVICE

Throttle Plate

Remove any sign of water from engine. Fill oil pan to full level with correct grade of engine oil. Inspect spark plugs. Add fuel to tank and charge fuel system.

Idle Air

The main jet in carburetor is stationary and needs no adjustment. Adjustment of the needle for idle jet should be made for best low speed operation while carburetor throttle is held closed by hand. T urning needle in nearer to its seat results in a heavier concentration. Turning needle out away from its seat results in a lighter concentration (Fig. 5–7).

Idle Fuel (Pick–Up Passages)

5–6 CARBURETOR RECONDITIONING (Fig. 5–8)

5–7 TO DISASSEMBLE THROTTLE BODY

10 11 12 8 7 3

4 2

2. Remove float shaft from opposite side. Remove float assembly (Item 4) and fuel valve needle.

21 6

17

3. Remove bowl to housing gasket (Item 2) from the machined surface of throttle housing (Item5) then remove venturi (Item 6).

18

23

22

4. Remove fuel valve seat (Item 7) with its fiber washer (Item 8).

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9

5

1. Push against end of float shaft (Item 3) at side of hinge bracket to force shaft through hinge bracket (Fig. 4). Use a small screwdriver.

5. Remove idle adjustment needle (Item 9) and friction spring (Item 10) from side of throttle housing (Item 5).

A–01810

Fig. 5–7 Carburetor Adjustment

1. Use a screwdriver to remove the four bowl assembly screws (Item 1) and lock washers.

2. Raise throttle housing and separate bowl to body gasket (Item 2) from fuel bowl assembly, then lift off throttle housing carefully to prevent damage to floats.

Idle Adjusting Needle

Idle Jet

16 14 1

20 15

13 PI–01231

Fig. 5–8 Carburetor Breakdown –5–2–

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

5–5 CARBURETOR ADJUSTMENT

6. Turn the throttle stop screw out (Item 1) 1 until it is flush with end of lever (Item 12). Close throttle and mark levers and throttle body as a guide when assembling parts.

NOTE: Do not remove throttle plate, throttle shaft and lever assembly, or throttle packing holders from the throttle housing unless the shaft is bent or other parts of assembly are damaged.

5–8 DISASSEMBLY OF THE FUEL BOWL 1. Remove the 1/2 inch (12,7 mm) plug (Item 13) from the bottom of the fuel bowl. Remove the fiber washer (Item 14).

2. Remove main jet (Item 15) and fiber washer (Item 16) from the threaded passage near the bottom of fuel bowl.

3. Remove main outlet jet (Item 17) with its fiber washer (Item 18) from center of fuel bowl (11/32 inch (8,6 MM) wrench to remove).

4. Mark the choke bracket (Item 19), choke lever (Item 20) housing as a guide to correct assembly.

and air intake

6. Remove choke bracket screws and choke bracket.

Clean all metal parts, using a carburetor parts cleaner . Wash in solvent. Clean out all passages and channels in carburetor with air. Reverse air flow through each passage to remove all dirt.

NOTE: Never use a hard wire or drill to clean out jets. Inspect all parts and install any damaged or worn parts. A repair kit should be used. For correct repair kit, see Bobcat Parts Book.

5–9 TO ASSEMBLE FUEL BOWL AND INTAKE ASSEMBLY 1. Install choke shaft seal and holder using a bushing driver todrive holder into housing until even with machined surface (Fig. 5–8). Follow same procedure for other side.

2. Install choke shaft (Item 23) through seals and holders in position in intake air body. Install choke plate (Item 22) in cut out of choke shaft. Check that choke plate release valve is in same position as when it was disassembled. Install choke plates screws using a small screwdriver.

Dealer Copy -- Not for Resale

5. Remove choke lever spring (Item 21). Close choke and remove choke plates screw (Item 22), choke plate and shaft (Item 23). (Note the position of choke plate stop in air intake).

3. Put choke shaft bracket (Item 19) over choke shaft and fasten bracket to air intake in same position as when removed. Tighten screws.

4. Fasten choke lever spring (Item 21) to choke lever and choke bracket.

5. Put fiber washer (Item 18) over threads of main outlet jet (Item 17). Install main outlet jet in bowl assembly and tighten.

6. Put fiber washer (Item 16) on main jet (Item 15) and install main jet in threaded hole near bottom of bowl.

7. Install hex plug (Item 13) and gaskets (Item 14) and tighten.

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5–10 TO ASSEMBLE THROTTLE BODY 1. Install throttle shaft seals and holding caps if these were removed during disassembly. Using a bushing driver, lightly drive caps into housing untileven with machined surface (Fig. 5–9).

2. Install throttle shaft and lever assembly (Item 12) into throttle housing.Turn shaft to fully open position.

3. Install throttle plate (Item 24) and turn to closed position. Hold plate with fingers and start throttle plate screws (Item 1 1). Tighten them loosely with a small screw driver. Center throttle plate in throttle bore and tighten screws.

NOTE: Make sure bevel edges of throttle plate fit throttle bore when throttle plate is closed.

Bushing Driver

B–02589

Fig. 5–9 Cap For Throttle Seal

4. Install idle adjustment needle (Item 9) and friction spring (Item 10) into the threaded passage at side of throttle side of throttle housing. Turn needle in slightly against its seat. Then, back needle out 1–1/4 turns as a temporary adjustment.

1–5/32’’

6. Put on a new throttle housing to fuel bowl gasket (Item 2) on machined surface of bowl cover. Install fuel valve needle (Item 7) on its seat.

7. Install float assembly (Item 4) in position with float lever bushing in line with holes in hinge bracket. Install float shaft (Item 3).

8. For correct adjustment of fuel level in floatchamber, check distance from the top of floats to machined surface of body (with not gasket) (Fig. 5–10). To make adjustment use a needle nose pliers and bend lever on float body.

NOTE: Do not bend or apply pressure to float bodies. When visually seen from their free end, float bodies must be centered at right angles to machined surface and must move free on float shaft.

9. Install large opening end of venturi (Item 6) into throttle bore and position venturi so the machined flat surface will be toward fuel bowl when bowl is assembled.

A–01800

Fig. 5–10 Check Float Level Idle Discharge Holes

Throttle Plate Idle Air

Idle Jet

Idle Adjusting Needle

5–11 ASSEMBLY OF FUEL BOWL AND THROTTLE BODY 1. Place fuel bowl assembly on throttle housing assembly and put holes in alignment in bowl flange with hole in gasket and cover.

Idle Fuel (Pick–Up Passages)

A–01810

Fig. 5–11 Throttle Adjustment

2. Install four assembly screws and (Item 1) tighten them evenly.

3. Hold throttle lever in closed position and turn throttle stop screw (Fig. 5–11) in until it contacts stop pin on throttle body. Turn screw in 1–1/2 more turns as a preliminary adjustment. Install carburetor using three gaskets between carburetor and intake manifold.

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Dealer Copy -- Not for Resale

5. Turn throttle housing and install fuel valve seat (Item 7) and fiber washer (Item 8).

5–12 LP CARBURETOR SERVICE The final regulator is built into the carburetor assembly. Fuel is measured to the carburetor jets above pressure of atmosphere. The throttle shaft bearings are provided with rubber seals.

5–13 CARBURETOR REMOVAL 1. Shut off fuel valve on fuel tank (Fig. 5–12).

2. Remove muffler from exhaust manifold.

3. Remove fuel line from carburetor and remove air cleaner hose.

B–02170

4. Remove choke and throttle linkage.

Fig. 5–12 LP Fuel Tank Shut–Off

5. Remove carburetor to manifold holding bolts and remove carburetor.

5–14 LP CARBURET RECONDITIONING (Fig. 5–13)

OR

The following tools are required for LP carburetor repair:

9

1. C–166–52 alignment studs.

2

3. C–161–194 gauge.

fuel valve lever

3 6

11

(Get these tools from Zenith Carburetor Dealers.)

5–15 DISASSEMBLY PROCEDURE LP CARBURETOR

4

1

8

5

1. Turn throttle stop screw to left until throttle plate is fully closed (Item 1).

2. Remove throttle plate screws (Item 2) and throttle plate (Item 3).

7

13

3. Remove throttle shaft seal holders and seals (Item 4).

15 12

10

4

Dealer Copy -- Not for Resale

2. C–161–193 main jet wrench.

14

4. Take out venturi holding screw (Item 5) and remove venturi (Item 6).

5. Remove choke plate screw, choke plate and choke shaft (Item 7).

B–01421

Fig. 5–13 LP Carburetor Parts

6. Remove idle adjustment needle and spring (Item 8).

7. Remove diaphragm cover assembly screws and complete diaphragm assembly (Item 9).

8. Pull apart diaphragm assembly parts (Item 10).

9. Remove shaft holder, fuel valve shaft and fuel lever (Item 11).

10. Inlet orifice is held in position with a 8/32 allen screw . Loosen this screw before removing inlet orifice (Item 12).

11. Remove inlet fuel valve stem and spring (Item 13).

12. Remove adjustment needle from main jet adjustment assembly (Item 14).

13. Use a 5/8 inch socket wrench to remove main jet adjustment housing (Item 15).

14. Use main jet wrench C–161–193 to remove main jet (Fig. 5–14).

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5–16 CLEANING AND INSPECTION Clean remaining parts in a parts cleaner fluid and inspect for evidence of wear or damage. Install all parts contained in repair kit and replace any damaged parts. Repair kit #6519218 contains all common items to be installed.

Main Jet Tool (C–161–193)

5–17 ASSEMBLE LP CARBURETOR

2. Place a new fiber washer on main jet adjustment body . Install and tighten with a 5/8 inch socket wrench (Fig. 5–14).

Adjustment O–ringFiber Washer Needle

A–01813

Fig. 5–14 Install Main Jet

3. Put a new O–ring on main jet adjustment needle.urn T the adjustment needle until it lightly contacts the seat, then back it out two to three turns (Fig. 5–14).

Fuel Valve Lever

4. Put a new rubber seal on fuel valve stem (Fig. 5–15).

Fuel Valve

5. Install fuel valve spring on fuel valve and install valve, spring end first into housing (Fig. 5–13).

6. Place a new O–ring on inlet orifice and turn part way into housing (Fig. 5–18).

Seal

7. Install top of fuel valve lever into groovein valve stem. Install shaft and shaft holder (Fig. 5–15).

8. Put gauge C–161–194 on machined surface of housing. Make adjustment of fuel valve lever to the .045–.055 inch (1,2–1,4 mm) position on gauge by turning inlet orifice in or out (Fig. 5–17). Holdposition by tightening 8/32 allen set screw (Fig. –5–18).

A–01814

Fig. 5–15 Reassembling Fuel Valve

Carburetor Body

9. Install three alignment studs (Tool C–166–52) in housing (Fig. 5–19).

Diaphragm

Screw

O–ring Inlet Orifice

A–01812

Fig. 5–16 Diaphragm Assembly 108 of 216

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Dealer Copy -- Not for Resale

1. Install main jet with tool C–161–193 (Fig. 5–14).

10. Note location of vacuum hole and vent channel hole. Install parts so that all holes are in correct alignment (Fig. 5–19). a. Gasket (Item 1).

Set Screw

b. Inner diaphragm, spacer cup out (Item 2). c. Diaphragm spacer , recessed side out (Item 3). d. Outer diaphragm, diaphragm plate in (Item4). e. Diaphragm, cover (Item 5) Gauge (C–161–194) A–01815

Fig. 5–17 Adjust Fuel Valve

Fig. 5–18 Adjust Fuel Valve Lever

12. Install venturi and fasten with venturi screw (Fig. 5–13, Item 6) 13. Install throttle shaft seal and seal caps. Press caps into position and use a center punch to keep them in place.

A–01816

Vacuum Holes

Alignment Studs (C–166–52) 5 4 3

1 2

14. Install throttle plate.

Vent Channel

15. Install idle adjustment screw and spring. Turn the adjusting screw in until it lightly contacts the seat, then back the screw out 1–1/2 to 2 turns.

Dealer Copy -- Not for Resale

11. Install three diaphragm screws, then remove alignment studs and install other screws (Fig. 5–20).

A–01817

Fig. 5–19 Diaphragm Assembly Installation 16. Install new choke spring.

17. Install choke shaft and choke plate.

Alignment Studs

18. Turn throttle stop screw clockwise and make adjustment of throttle for fast idle.

Screws A–01818

Fig. 5–20 Install Diaphragm Screws 109 of 216

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600, 600D, 610, 611 Loader Service Manual

5–18 VAPORIZER & PRIMARY REGULATOR SERVICE Regulator

The vaporizer (Fig. 5–21) consists of a high pressure regulator and vaporizer combined in a single unit. The high pressure regulator reduces LPG fuel tank pressure to an even outlet pressure. The vaporizer section changes the liquid fuel into a gas.

WARNING

Close the fuel valve at the fuel tank before removing the vaporizer.

W–2274–1297

5–19 DISASSEMBLING THE VAPORIZER

2 3 4

A–01820

2. Remove the inlet orifice fitting (Item 11) and aluminum washer (Item 12) from inlet bore.

7

3. Loosen lock nut (Item 3) on adjustment screw (Item 2) and turn screw all the way in to press the inlet valve seat.The valve seat in its normal position will prevent removal of the inlet orifice.

4. Turn a 1/4’’–20 screw into inlet orifice block and remove block (Item 13).

Vaporizer

5

18 11

Fig. 5–21 Vaporizer and Regulator

9

Diaphragm

8

10 20

14

6

19

16

17

15

12 13 NOTE: The spring loaded inlet valve seat must be fully pressed in during this operation to prevent damage to both the seat and orifice block.

21 22 Piston A–01822

Fig. 5–23 Aligning Piston

5. Remove pressure adjustment screw (Item 2) and spring (Item4).

6. Remove six diaphragm screws (Item 5) and the diaphragm cover (Item 6).

B–01225

Fig. 5–22 Vaporizer Breakdown

7. Lift rubber diaphragm (Item 9) with assembled piston from bore. Remove screw (Item 7) that holds diaphragm and holding plate to piston.

8. Reverse vaporizer assembly (Item 15) and remove inlet valve seat, holding spring and valve cap 16 & 19.

9. Remove large O–ring (Item 21) from its groove on outside of housing.

Button

vaporizer

5–20 TO ASSEMBLE THE VAPORIZER 1. Put a new diaphragm (Item 9) over piston (Item 20) and put holding plate (flange up) on diaphragm. Fasten parts with diaphragm screw but do not tighten.

2. Check condition of inlet orifice (Item 13). When damaged at orifice shoulder , install new.

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Spring A–01821

Fig. 5–24 Installing Button and Spring 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

1. To remove the vaporizer element, put the vaporizer in a vise and remove the 1–1/4 inch brass nut (Fig. 5–27) with a socket wrench.

3. Put inlet orifice block into its bore temporarily. This part has a groove and slides on a dowel pin in bore to prevent part from being installed wrong.

4. Put assembled diaphragm and piston into bore (Fig. 5–23) so that piston centers over inlet orifice block without rubbing against it.

5. Make alignment of six screw holes in diaphragm with holes in vaporizer top and tighten diaphragm (Fig. 5–23). Hold diaphragm and holding plate to keep them from moving when tightening screw.

6. Remove assembled diaphragm and piston and inlet orifice block from their bores after correct alignment has been made.

A–01835

Fig. 5–25 Adjustment of Vaporizer

7. Check inlet valve seat. When neoprene disc is damaged or worn, install a new, complete unit (Fig. 5–22, Item 14).

9. Install assembled diaphragm and piston into bore after installing O–ring on piston. Put light film of oil over seal for easier installation. Check piston alignment by looking into inlet orifice bore. Y oke of piston should line up with inlet orifice bore and six diaphragm holes with the holes in top of vaporizer (Fig. 5–23).

10. Install cover over diaphragm and fasten it with six screws. Put spring for adjustment screw (Item 4) into bore through top of cover and install adjustment screw in lock nut (Item 3).

11. Turn adjustment screw all the way in to press in on the inlet seat.

12. Install a new filter washer on inlet orifice block and insert block in bore using groove as a guide. Remove 1/4 inch –20 screw from assembled valve (Fig. 5–23).

13. Put a new aluminum washer into orifice bore. Turn inlet orifice retainer into bore and tighten. Install a new large O–ring into groove on outside of vaporizer assembly (Item 21).

Dealer Copy -- Not for Resale

8. Put small button on spring and install button end of spring into inlet valve seat. Install parts into bore (Fig. 5–24).

14. Install a new O–ring in vaporizer head of cooling element. Install fiber washer and 1–1/4 inch brass nut. Tighten it, using a socket wrench.

5–21 ADJUSTMENT OF VAPORIZER NOTE: The correct working pressure adjustment for vaporizer is 12 PSI (,84 Kgf/cm@) (gauge pressure).

1. Put assembly in a vise. Connect an air hose which will supply 75 PSI (5,3 Kgf/cm@) to inlet fittings (Fig. 5–25).

2. Connect a 0 to 30 or a 0 to 50 PSI (0–2,1 or 0,3,5 Kfg/cm@) pressure gauge to outlet.

3. Back off vapor adjustment screw until one or two threads are holding screw to cover. Put air pressure to unit (Fig. 5–25).

4. Turn pressure adjustments in slowly until 12 PSI (,84 Kfg/cm @) shows on gauge.

NOTE: When making pressure adjustment, be sure air has been removed from regulator. Vent out the air by loosening the pressure gauge.

5. When all connections are tightened and adjustment has been made as above, put soap water over the vent hole in the diaphragm cover . Air will appear if diaphragm is leaking.

6. After adjustment has been made, tighten lock nut on pressure adjustment screw. Turn off air pressure and remove gauge and air ling (Fig. 5–25).

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5–22 LP FUEL FILTER LOCK–OFF The filter lock–off is actuated when ignition key is turned on. A filter element is located inside the unit. The unit must be removed and disassembled to clean or install a new element.

WARNING

Tank Lock

Close the fuel valve at the fuel tank before removing the filter lock–off.

W–2273–1297

5–23 FUEL FILTER LOCK–OFF DISASSEMBLY

Filter Lock

1. Close hand valve on tank (Fig. 5–26).

B–01968

2. Remove filter assembly from fuel tank (Fig. 5–26).

Fig. 5–26 Tank and Filter Lock–Off

3. Remove solenoid by putting filter housing in a vise and loosening 5/8 inch hex brass element (Item 1). Remove solenoid section (Item 5).

4. Hold filter housing in a vise and use wrench to screw out the filter inlet (Item 12). It has a 3/4 inch square nut.

9

1

2

5

4

3

14

6

10

11

12

Dealer Copy -- Not for Resale

NOTE: When cleaning filter remove complete solenoid first to keep dirt from entering solenoid section.

7 8

13

B–01171

Fig. 5–27 Filter Lock–Off Parts 5. Remove filter element and clean any dirt out of filter housing. Clean element (Fig. 10) by forcing compressed air to it from inside out. Inspect O–ring (Item 11) for damage.

6. Install clean or new filter element inside filter housing (Item 9). Check that it is correctly seated. Lubricate O–ring with a light mineral oil. T urn filter inlet completely in by hand then tighten it to 30–40 ft.–lbs. (40,68–54,24 Nm) torque.

7. Assemble solenoid section to filter housing using a maximum of 18 ft.–lbs.

(24,408 Nm) torque to tighten. Oil O–ring (Item 8) on filter housing to keep it from being damaged.

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5–24 ENGINE RECONDITIONING Clean engine and all parts remove all dirt between fins.

and

5–25 REMOVAL OF ENGINE 1. Disconnect fuel line, wiring and throttle choke linkage.

2. Remove drive belt.

3. Remove engine fastening bolts.

Use a hoist to remove engine from loader (Fig. 5–28).

C–02178

Fig. 5–28 Remove Engine From Loader 5–26 REMOVAL ACCESSORIES

OF Flywheel

Dealer Copy -- Not for Resale

Remove the engine oil filter , starter, hydraulic pump, variable speed sheave and other installed parts.

(See Variable Speed Sheave Removal, Page 3–18).

5–27 REMOVAL OF FLYWHEEL 1. Remove the flywheel screen (Fig. 5–29).

2. Remove the flywheel nut and washer (Fig. 5–29).

3. Pull flywheel of f of taper on crankshaft. (Use a softhammer to loosen flywheel (Fig. 5–30).

B–02584

Fig. 5–29 Remove Flywheel Nut & Washer

A–01823

Fig. 5–30 Remove Flywheel

5–28 REMOVAL OF AIR HOUSING (Fig. 5–31) 1. Remove cylinder head covers (Item 1).

2. Remove bolts holding flywheel housing to lower cylinder housing (Item 2).

3. Remove bolts holding the flywheel housing to gear cover (Item 3).

A–01841

Fig. 5–31 Remove Air Housing 113 of 216

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600, 600D, 610, 611 Loader Service Manual

5–29 REMOVAL OF CARBURETOR AND MANIFOLD 1. Remove manifold nuts (Fig. 5–32).

2. Lift off sections (Fig. 5–32).

5–30 REMOVAL OF CYLINDER HEAD 1. Remove head bolts (Fig. 5–33).

2. Lift heads from engine.

NOTE: Bolts are of different lengths and must be installed according to the bosses on heads.

A–01830

Fig. 5–32 Remove Manifold 5–31 REMOVAL OF GEAR COVER Cylinder Head

1. Disconnect governor linkage.

2. Remove gear cover bolts (Fig. 5–34.)

4. Remove cover.

5–32 REMOVAL OF CAMSHAFT 1. Remove three bolts and washers (Fig. 5–35).

lock

2. Pull gear from shaft (Fig. 5–35).

NOTE: Camshaft gear has offset hole to aid in assembly.

5–33 REMOVAL OF IDLER AND SHAFT

B–02590

Fig. 5–33 Remove Cylinder Head

Camshaft Gear

A–01838 Gear Cover Fig. 5–34 Remove Gear Cover

Gear

GEAR

Gear Puller

1. Remove allen set screw (Fig. 5–36).

2. Remove idler gear and shaft using a gear puller (Fig. 5–36).

5–34 REMOVAL OF OIL PAN 1. Turn engine so that it rests on the cylinder block (Fig. 5–37).

A–01824

Fig. 5–35 Remove Camshaft Gear

A–01842

Fig. 5–36 Remove Idler Gear

2. Remove bolts (Fig. 5–37).

Pipe Plug

5–35 REMOVAL OF OIL PUMP

Oil Pump

1. Remove lock nut and pump drive gear from shaft.

2. Remove groove pipe plug from bottom of oil pan (Fig. 5–38).

3. Use a 5/32 allen wrench to remove the lock nut from pipe plug hole (Fig. 5–38).

Oil Pan

4. Remove oil pump.

A–01834

Fig. 5–37 Remove Oil Pan 114 of 216

–5–12–

Lockscrew

A–01831

Fig. 5–38 Remove Oil Pump 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

3. Drive out two dowel pins (Fig. 5–34).

5–36 REMOVAL OF PISTONS AND CONNECTING RODS

Connecting Rod Cap

1. Use a 1/2 inch socket wrenchto loosen and remove hex nuts from connecting rods (Fig. 5–39).

2. Hit ends of bolts lightly to release connecting rod cap (Fig. 5–39).

3. Remove carbon that might interfere with removal of pistons from upper end of cylinders (Fig. 5–40).

4. Turn crankshaft until piston isat the top of its stroke.

B–02582

B–02581

Fig. 5–39 Remove Connecting Rod Caps

Fig. 5–40 Remove Carbon From Cylinder Walls

5. Push connecting rod and piston assembly upward and out through top of cylinder (Fig. 5–41).

Dealer Copy -- Not for Resale

6. Put cap back on connecting rod to keep them together.

5–37 REMOVAL OF VALVES AND SEAT INSERTS 1. Remove valve tappet inspection plate and push the valve spring together with an automotive valve lifting tool (Fig. 5–42).

Piston Assembly

2. Put rag into opening at bottom of valve chamber so holding locks do not fall into engine pan.

B–02585

Fig. 5–41 Remove Rod and Piston 3. Remove holding locks, seats, springs, valves and clean in solvent.

NOTE: Mark valves so that they will be put in same guide during assembly as they were when removed.

Valve Lifter Valves

4. Remove inlet and exhaust valve inserts when badly worn.

5. Inspect valve guides for wear and remove when valves stem clearance is more than .006 inch (,152 mm) (Fig. 5–43). Use a driver to drive out old guides.

A–01827

Fig. 5–42 Remove Valves 115 of 216

–5–13–

A–02543

Fig. 5–43 Check Valve Guides 600, 600D, 610, 611 Loader Service Manual

5–38 REMOVAL OF CYLINDER BLOCK 1. Remove four holding nuts from cylinder block (Fig. 5–44).

2. LIft off cylinder blocks 5–39 REMOVAL OF CRANKSHAFT 1. Remove six bolts in main bearing plate and remove plate (Fig. 5–45).

B–02588

Fig. 5–44 Remove Cylinder Block Nuts

2. Pull crankshaft from end of housing (Fig. 5–45).

5–40 REMOVAL OF CAMSHAFT

Crankshaft

1. The camshaft must be pulled from flywheel end of engine (Fig. 5–46).

5–41 REMOVAL OF VALVE TAPPET 1. After camshaft has been taken out, remove the valve tappets (Fig. 5–46).

B–01843

Fig. 5–45 Remove Crankshaft 5–42 ASSEMBLY OF ENGINE AFTER RECONDITIONING INSTALLATION OF VALVE TAPPETS Camshaft 1. Install valve tappets into proper position before camshaft is installed (Fig. 5–46).

NOTE: Valve tappet adjustment should be made after cylinder locks have been installed with engine cold.

The clearance should be .008 inch (,2 mm) for the inlet and .016 (,4 mm) for the exhaust valves.

5–43 INSTALLATION OF CAMSHAFT 1. Install spring and plunger in place at end of camshaft (Fig. 5–46).

2. Push camshaft in thru flywheel end of engine (Fig. 5–46).

Valve Tappets

A–01846

Fig. 5–46 Install Tappets and Camshaft 116 of 216

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600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

Main Bearing Plate

5–44 INSTALLATION OF CRANKSHAFT

Valve Lifter

Valve Stem

1. Put crankshaft in through end of housing (Fig. 5–45).

2. Install the main bearing plate using the same quantity and thickness gaskets and shims as when removed. End play must be .002–.004 inch (,05–,10 mm) when engine is cold.

NOTE: Holes for fastening bolts in the main bearing plate are located so that the plate will be correctly installed formain bearing lubrication.

3. Install six bolts in the main bearing plate and tighten to 25–30 ft.–lbs.

(33,85–40,67 Nm) torque.

5–45 INSTALLATION OF VALVES AND SEAT INSERTS

A–01827

Fig. 5–47 Install Valves

1. Inspect all valve inserts and install new when necessary.

2. Install each valve into same guide from which removed.

Dealer Copy -- Not for Resale

3. Install holding locks, seat, spring and valves (Fig. 5–47).

4. Remove rag in opening at bottom of valve chamber.

5. Install inspection plate for valve tappets.

5–46 INSTALLATION OF CYLINDER BLOCKS 1. Install cylinder blocks and fasten each with four holding nuts (Fig. 5–48).

B–02588

Fig. 5–48 Install Cylinder Block 2. Tighten nuts to 40–50 ft.–lbs.

(54,23–67,79 Nm) torque.

Compression Ring

5–47 INSTALLATION OF PIST ON RINGS 1. Place open end of piston first and spread to fit in groove (Fig. 5–49).

Scraper Ring Oil Ring

2. There are four rings to each piston. The fourth (bottom) ring is the oil ring, the third is the scraper ring, second is a compression ring and the first is a compression ring (See Fig. 5–50).

3. Install the scraper ring with scraper edge down (Fig. 5–50).

A–01826

Fig. 5–49 Install Piston Rings 117 of 216

Revised March 80

–5–15–

A–01844

Fig. 5–50 Piston Ring Sequence 600, 600D, 610, 611 Loader Service Manual

5–48 INSTALLATION OF PISTONS AND CONNECTING RODS NOTE: Identical numbers are stamped on the side of each connecting rod and its cap. These numbers must all be on the same side of connecting rods when installed in the engine. Be sure the hole in the cap is facing toward the oil spray nozzle (Fig. 5–51). Install new nuts on the connecting rod bolts and tighten to 20–28 ft.–lbs. (27,11–37,96 Nm) torque.

Oil Hole

Oil Spray Nozzle

A–01859

Fig. 5–51 Install Rod Caps

Ring Compressor

B–02586

Fig. 5–52 Using Ring Compressor

1. Install piston and connecting rod assembly in the same bore as when removed.

Piston

Dealer Copy -- Not for Resale

NOTE: Oil the pistons, rings, wrist pins, rod bearings and cylinder walls before assembly.

2. Use a ring compressor and check that ring gaps are 90 ° apart around the piston (Fig. 5–52).

3. Check that wide sections of the piston skirt are toward the maximum thrust side (Opposite the crankshaft rotation) (Fig. 5–53).

4. Install connecting rod cap with bearing half (Fig. 5–51).

5. Install rod bearing holding nut and tighten to 20–28 ft.–lbs.

(27,11–37,96 Nm) torque.

5–49 INSTALLATION PUMP

OF

Wide Thrust Face Opposite Crankshaft Rotation

OIL

1. Install oil pump into crankshaft housing (Fig. 5–54). Be sure that the seat for the lock screw is in line with the hole for the screw in the crankshaft housing.

Connecting Rod C–01660

Fig. 5–53 Piston Position Pipe Plug

2. Install the lockscrew into pipe plug hole (Fig. 5–55). Use a 5/32 inch allen wrench to tighten lock.

Oil Pump

3. Install the grooved pipe plug from bottom of housing (Fig. 5–55).

5–50 OIL PAN INSTALLATION 1. Install bolts and tighten to 6–9 ft.–lbs. (8,13–12,2 Nm) torque.

Oil Pump Fig. 5–54 Install Oil Pump

118 of80 216 Revised March

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B–02580

Lockscrew Fig. 5–55 Install Pipe Plug

A–01831

600, 600D, 610, 611 Loader Service Manual

5–51 INSTALLATION OF IDLER GEAR AND SHAFT 1. Install idler gear and shaft (Fig. 5–56).

2. Check that oil groove and shaft is in up position, and clearance between idler gear bearing (inner race) and shoulder of shaft is .0015–.0035 inch (0,0381–0,0889) (Fig. 5–57).

3. Install the allen set screw (Fig. 5–57A).

5–52 INSTALLATION CAMSHAFT GEAR

Idler Gear B–02574

Fig. 5–56 Install Idler Gear

B–03139

Fig. 5–57 Bearing Adjustment

OF

1. Put gear on shaft so that holes are in correct alignment (Fig. 5–58).

Set Screw

Camshaft Spring

Gear

Dealer Copy -- Not for Resale

NOTE: Be sure the spring and plunger is in place (Fig. 5–58).

Plunger

2. Install three bolts and lock washers (Fig. 5–58).

5–53 INSTALLATION OF GEAR COVER 1. Install cover.

2. Install gear cover bolts and two dowel pins. tighten bolts to 14–18 ft.–lbs. (18,98–24,4 Nm) torque (Fig. 5–59).

3. Connect governor linkage rod.

5–54 INSTALLATION CYLINDER HEAD

B–02576

Fig. 5–57A Setscrew For Idler Gear Shaft

B–02393

Fig. 5–58 Install Camshaft Gear

OF Gear Cover

1. Install cylinder head.

15

NOTE: Oil all cylinder head bolts to protect them from rust.

14

4. Tighten cylinder head bolts to 22–24 ft.–lbs. (29,82–32,54 Nm).

9 13

3 16

3. Tighten head bolts in sequence shown (Fig. 5–60).

5

7

11

2. Install bolts, putting lengths according to bosses on cylinder heads (Fig. 5–60).

10

1 2

4

6

17

8

B–02578

Fig. 5–59 Install Gar Cover 119 of February 216 Revised 80

–5–17–

12

B–02577

Fig. 5–60 Install Cylinder Head 600, 600D, 610, 611 Loader Service Manual

5–55 INSTALLATION OF CARBURETOR AND MANIFOLD ASSEMBLY

610,611ServiceManual#6556276–WisconsinEngineServiceSection

1. Install manifold assembly on engine (Fig. 5–61).

2. Install manifold nuts and tighten to 14–18 ft.–lbs. (18,98–24,4 Nm).

5–56 INSTALLATION HOUSING

OF AIR

1. Install bolts for holding the flywheel housing to gear cover.

2. Install bolts for holding flywheel housing to lower cylinder covers (Fig. 5–62).

A–01830

Fig. 5–61 Install Manifold Assembly

5–57 INSTALLATION FLYWHEEL

Dealer Copy -- Not for Resale

3. Install cylinder head covers (Fig. 5–62).

OF

1. Push flywheel on taper of crankshaft.

Check that woodruff key is in position on shaft and is in alignment with groove in flywheel bore (Fig. 5–63).

2. Install flywheel nut and washer and tighten to 40–60 ft.–lbs.

(54,23–81,34 Nm) torque.

A–01841

Fig. 5–62 Install Air Housing

3. Install flywheel screen (Fig. 5–63).

5–58 INSTALLATION ACCESSORIES

OF

Install engine oil filter , hydraulic pump variable sheave and other parts.

starter, speed

B–02584

Fig. 5–63 Install Flywheel 120 of 216 Revised February 80

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600, 600D, 610, 611 Loader Service Manual

Paragraph Page Number Number ASSEMBLE THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 ..

6–6 CHECKS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . .6–2 .

6–1 COMPRESSION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2.2 ..

6–2 CONNECTING ROD BEARING CHECK AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.10 ..

6–24 COOLING AIR BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.16 ..

6–29 CRANKCASE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–5.3 ..

6–17 CRANKSHAFT AND BEARING CHECKS AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–5.5 ..

6–19 CRANKSHAFT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.1 ..

6–17 CRANKSHAFT RECONDITIONING . . . . . . . . . . . . . . . . . . . . 6–5.2 .

6–17 CYLINDER CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–5.12 ..

6–25 CYLINDER HEAD REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.14 ..

6–26 ENGINE RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . .6–3 .

6–4 FRONT COVER CHECK AND REPAIR OF ENGINE GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.8 ..

6–20 FUEL INJECTION NOZZLE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–5.17 ..

6–30 FUEL INJECTION PUMP CHECK . . . . . . . . . . . . . . . . . . . . . .6–2.4 .

6–2 FUEL SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2.3 ..

6–2 GENERAL ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 ..

6–31 GOVERNOR CHECK AND REPAIR . . . . . . . . . . . . . . . . . . . . 6–5.9 .

6–23 MAIN BEARING CHECK AND INSTALLATION . . . . . . . . . . . . 6–5.4 6–18 NEW GEAR STARTER RING ON FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .6–5.7 .

6–20 OIL PUMP CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.6 ..

6–20 PISTON CHECK AND MEASURING . . . . . . . . . . . . . . . . . . . . 6–5.13 .

6–25 PISTON PIN BUSHING CHECK AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.11 ..

6–25 ROCKER ARM REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.15 ..

6–29 START OF FUEL INJECTION ADJUSTMENT . . . . . . . . . . . . 6–2.6 6–3 T.D.C. AND START OF FUEL INJECTION . . . . . . . . . . . . . . . .6–2.5 6–3 TIGHTENING BOLTS AND STUDS . . . . . . . . . . . . . . . . . . . . . 6–1 .

6–1 VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . 6–2.1 .

6–1

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DEUTZ ENGINE SERVICE

DEUTZ ENGINE SERVICE

600, 600D, 610, 611 Loader Service Manual

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–6–0–

600, 600D, 610, 611 Loader Service Manual

6 DEUTZ (ENGINE RECONDITIONING) 6–1 INSTRUCTIONS FOR TIGHTENING BOLTS AND STUDS NOTE: All fasteners must first be tightened lightly to 14–21 ft.–lbs.(1.9–2.9 m*Kgf) torque. Tighten in sequence until correct adjustment has been made. Before assembling bolts and studs put oil on threads and surfaces of head or nut.

1. First tightening can be done using a socket wrench or box end wrench (Fig. 6–1 A).

2. Tightening must be done in correct sequence. A special tool (Deutz number 4689) can be used to check angle of turn when tightening (Fig. 6–1 B).

N–15889

A

B

N–15890

Fig. 6–1 Initial Tightening

3. Figure 6–2 shows angle of rotation in degrees.

NOTE: Drill a 3/8 inch (9,5 mm) hole in location shown in figure 6–2a to let water out of starter before it goes into main housing. Water in the starter causes circuit failure.

6–2 CHECK AND ADJUSTMENTS

6–2.1Adjustment Clearance

of V

alve

NOTE: The engine must be cold.

1. Loosen and remove bolts fastening cylinder head covers (Fig 6–2).

Dealer Copy -- Not for Resale

These adjustments can be made separately, usually after an engine has been reconditioned.

Drill Here N–15891

Fig. 6–2 Angle Of Rotation

C–01927

Fig. 6–2a Hole Location

2. Turn crankshaft so that valves of number one cylinder (on flywheel side) are in balance (both valves closed) (Fig. 6–4).

3. Mark position of overlap of number one cylinder on edge of V–belt pulley in alignment with line marked on engine housing (Fig. 6–5).

4. Turn crankshaft 360 degrees clockwise.

N–15892

Fig. 6–3 Removing Head Covers

N–15893

Fig. 6–4 Both Valves Closes

5. Check valves of first cylinder and make adjustment when needed.

Loosen lock nut on set screw of rocker arm. Make adjustment of set screws so feeler gauge has light resistance when passing between rocker arm and valve.

Valve clearance for inlet and exhaust is .006 inches (0,15 mm).

NOTE: After a cylinder unit repair has been done, valve clearance must be set on high side, .059 inches (1,5 mm).

6. Tighten lock nut without turning set screws.

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N–15894

Fig. 6–5 Marking Position of Overlap –6–1–

Fig. 6–6 Cylinder Head Cover Gasket 600, 600D, 610, 611 Loader Service Manual

7. Turn crankshaft through 540 degrees (1–1/2 turns). Make adjustment of valves on second cylinder.

8. When installing cylinder head covers, make sure gasket isin good condition.

Make sure packing rings are placed under holddown nuts (Fig. 6–6).

6–2.2 Compression Check Use a compression tester (Fig. 6–7). Compression must be 385–450 PSI (2564,57–3102,75 kPa).

Before checking, run engine at full speed so lubricating oil can seal combustion chambers. For test, the speed control lever must be back to fuel shut–of f position.

N–15895

Install adapter of compression tester in place of glow plug (Fig. 6–8).

6–2.3 Checking Fuel System A tank filled with fuel is required forthis test. It must be higher than injection pump when engine has beenremoved from loader.

1. Check fuel filter to make sure it is working. Check fuel flow after disconnecting line from filter outlet (Fig. 6–9).

N–15896

Fig. 6–8 Glow Plug

N–15897

Fig. 6–9 Filter Outlet

2. Loosen air vent screw in fuel injection pump. Let fuel topump flow until it is free of air (Fig. 6–10).

3. Remove cover for injection nozzle holder. Remove air housing (Fig. 6–11).

4. Loosen fuel line connection at nozzle holder (Fig. 6–12). Start engine or turn it by hand and check for fuel flow.

5. Assemble and tighten connections.

6–2.4 Checking Fuel Pump

all

N–15898

Fig. 6–10 Loosening Air Vent Screw

N–15899

Fig. 6–11 Removing Air Housing

Injection

When pump is installed, only tightness of pressure release valves and pumping elements can be checked.

1. Remove air housing (Fig.6–11), and disconnect fuel lines (Fig. 6–12).

2. Fasten pressure indicators (Deutz number 3202) to respective fuel lines on fuel injection pump.

3. Press excess fuel button (Fig. 6–13).

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Revised February 80

N–15900

Fig. 6–12 Loosening Fuel Lines –6–2–

N–15901

Fig. 6–13 Press Excess Fuel Button 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

Fig. 6–7 Checking Compression

The indication must not be lower than minimum specified values.

The pressure of both cylinders must be uniform 385–450 PSI (2564,57–3102,75 kPa).

NOTE: Before starting repair , make an inspection record to include results of compression check. Also list engine wear and new parts.

4. Turn crankshaft by engaging starter. Loosen plug and let out air pressure.

Tighten the plug (Fig. 6–14).

5. To check a pressure relief valve, turn engine to generate a pressure to 2130 PSI (149.7 Kgf/cm 2) and observe pressure gauge. The pressure must not decrease to less than 1990 PSI (139.9 Kgf/cm 2) within one minute.

6. To check pump element, turn crankshaft about five revolutions. Pressure should not be less than 4267 PSI (299 Kgf/cm 2).

7. Remove pressure indicator.

8. Connect fuel lines first locate tapes on adapter and turn on union nut (Fig. 6–15).

N–15902

Fig. 6–14 Releasing Air

9. Install air housing.

6–2.5 To Find top Dead Center And Start Of Fuel Injection 1. Check valve clearance and correct.

3. Use a screwdriver press down on valve of number one cylinder and put a piece of 5 to 6 millimeter (1/4 inch) steel plate between valve stem and rocker (Fig. 6–16).

4. Turn crankshaft clockwise until piston makes contact with proper valve.

5. Mark position of crankshaft on edge of V–belt pulley dead–center mark on crankcase (Fig. 6–17).

, in line with cast

Dealer Copy -- Not for Resale

2. Turn crankshaft so piston and number one cylinder are at point of maximum compression (Firing Point) before TDC.

N–15903

Fig. 6–15 Reconnecting Fuel Lines

6. Remove piece of steel plate. Turn crankshaft about 90°. Install piece of steel plate between same valve stem and rocker .

Rotate crankshaft counterclockwise until piston again makes contact. Mark second position.

7. Remove piece of steel plate and install cylinder head covers.

8. With a flexible steel rule measure and mark half way position between two marks (6–18).

9. Using a flexible steel rule from TDC indicator, mark distance to start of delivery. Mark in clockwise direction of rotation. Start of delivery is 150 PSI (10.6 Kgf/cm 2) (Fig. 6–19).

6–2.6 Adjustment Of Start Of Injection

B–02201

Fig. 6–16 Determining Top Dead Center

PI–02052

Fig. 6–17 Marking Crankshaft Position

Fuel

Put a mark on edge of V–belt pulley at point which fuel injection starts.

1. Remove air housing and disconnect fuel injection lines (Fig. 6–11.)

B–02205

Fig. 6–18 Marking Half–Way Position 125 of 216

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PI–01983

Fig. 6–19 Marking Start Of Delivery 600, 600D, 610, 611 Loader Service Manual

2. With engine located on repair bench, connect a tank of dieselfuel to fuel filter inlet (Fig. 6–20). (Tank must be higher than inlet.)

3. Turn engine to remove air from fuel supply system (use tool Deutz number 320°) (Fig. 6–21). then return first cylinder to the firing order before TDC. 4. Turn crankshaft slowly until level of fuel can be seen in capillary tubes.

NOTE: At the same time, the start–of–injection indicator on the V–belt pulley must be in line with the dead–center mark on the crankcase cover (Fig. 6–22).

N–15904

Fig. 6–20 Providing Fuel to Filter

PI–02070

Fig. 6–21 Bleeding Air From System

NOTE: One gasket 0.3 mm (.012 inches) thick corresponds to about 2 ° of crankshaft turn. Fuel injection will be advanced by removing gaskets and retarded by adding gaskets. One gasket must be left to act as a seal.

PI–02069

Fig. 6–22 Alignedwith Dead–Center Mark

PI–02068

Fig. 6–23 Adding or Deleting Shims

6. Before installing fuel injection pump, put fork of control lever into alignment with groove in housing (Fig. 6–24).

7. Install and secure injection pump with ball head of control rod facing control lever.

8. Check start of fuel injection and correct when needed.

9. Remove capillary tube.

PI–02044

Fig. 6–24 Aligning Fork with Recess

PI–01998

Fig. 6–25 Lock Down the Union Nuts

10. Connect fuel lines. In each case locate cone endof line and connecting stub and run union nut down finger tight, to make sure that cone is correctly seated. Tighten the union nuts (Fig. 6–25).

6–3 ENGINE RECONDITIONING Remove the following parts: Starter, generator, fuel filter with fuel line to injection pump, induction pipe, exhaust manifold, air housing, oil cooler, side cover plates, leak off pipe, fuel injection pipe and cooling air blower.

NOTE: To keep out foreign material put caps on connecting ends and delivery opening of injection pump (Fig. 6–26).

N–15906

Fig. 6–26 Keep Out Foreign Matter 126 of 216

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600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

5. For adjustment of the timing of the start–of–injection, remove the fuel injection pump. Increase or decrease the number of gaskets between the pump and cover (Fig. 6–23).

1. Remove injectors (Fig. 6–27).

2. Loosen cylinder headholddown bolts in diagonal sequence (Fig. 6–28), in steps. Remove cylinder head complete with studs and push rods protective tubes. (Use special wrench for holddown bolts, Deutz number 1310–02.)

3. Remove lower crankcase cover. Loosen and remove connecting rod bolts (Fig. 6–29).

N–15907

Fig. 6–27 Removing Injectors

Fig. 6–28 Removing Cylinder Head

4. Lift up bearing cap with a bar.

Pull cylinder with piston and connecting rod, from crankcase (Fig. 6–30).

5. Remove injection pump.

6. Remove V–belt pulley and flywheel.

7. Remove front cover Loosen only bolts around outside edge.

N–15908

Fig. 6–29 Removing the Big–End Bolts

N–15909

Fig. 6–30 Withdraw the Cylinder

8. Remove rear end shield, using tool for removing end shield on flywheel side (Deutz number 4683) (Fig. 6–31).

9. Remove loose governor plate and fly weights from governor.

Push the ball bearing with gear wheel and governor shaft out of crankcase (Fig. 6–32).

10. Put engine on it’s cylinder head contacting surface, while holding the loose camshaft.

Remove the camshaft.

B–02202

Fig. 6–31 Removing the End Shield

Dealer Copy -- Not for Resale

NOTE: The bearing must be protected against damage and must be marked on the back for correct assembly.

B–02200

Fig. 6–32 Removing the Governor

11. Remove crankshaft gear wheel. Remove bolt holding center bearing block (Fig. 6–33).

12. Remove crankshaft.

13. Remove bolt holding lube oil pump. Bolt is reached from underside of crankcase (Fig. 6–34).

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N–15910

N–15911

Fig. 6–33 Remove Center Bearing Block

Fig. 6–34 Remove Lube Oil Pump Screw

–6–5–

600, 600D, 610, 611 Loader Service Manual

14. Turn free pump so connecting end is opposite groove in bearing bore, then remove pump (Fig. 6–35).

15. Remove loose tappets.

16. Remove following parts from crankcase; retainers for seal rings of push rod cover , oil pressure switch, crankcase vent and lube oil pressure control valve.

N–15912

Fig. 6–35 Removing the Oil Pump

N–15913

Fig. 6–36 Remove the Slotted Plugs

17. Remove plugs with groove for camshaft lubrication, after which crankcase is ready for cleaning (Fig. 6–36).

All parts of disassembled engine must be cleaned and checked for damage. (See Inspection And Repair.) the crankshaft and camshaft bearing bushing must be pushed into engine housing.

N–15914

Fig. 6–37 Lock the Sealing Plug

N–15915

Fig. 6–38 Oil Pressure Switch

1. Use sealing plug for the camshaft oil way. Put it in even and hit with a center punch to lock (Fig. 6–37).

2. Install oil pressure switch (Fig. 6–38).

3. Install crankcase breather (Fig. 6–39).

4. Install breather housing using a new O–ring (Fig. 6–40).

5. Install breather tube crankcase (Fig. 6–41).

N–15916

Fig. 6–39 Install the Crankcase Breather

N–15917

Fig. 6–40 Install Breather Housing

to

6. Install oil pressure relief valve in housing. Use new gasket (Fig. 6–42).

N–15918

Fig. 6–41 Installing Breather Tube 128 of 216

–6–6–

PI–02067

Fig. 6–42 Install Oil Pressure Relief Valve 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

6–4 TO ASSEMBLE THE ENGINE

7. Check that same number is marked on housing andbearing cap and that both heavy duty retainer studs are available for assembly (Fig. 6–43).

8. Install bearing in housing and bearing cap. Check locating pin (Fig. 6–44).

9. Put motor oil onbearing and put bearing housing on middlemain bearing journal.

PI–02059

Fig. 6–43 Check Marks

N–15920

Fig. 6–44 Locating Pin

11. Put thrustwasher on front crankshaft bearing with lubricating oil ways facing crank and tab in groove in the crankcase. Put grease on washer to hold it in position (Fig. 6–46).

12. Put motor oil on front crankshaft bearing.

PI–01988

Fig. 6–45 Installing Cap Screws

PI–01989

Fig. 6–46 Installing Thrust Washer

13. Install crankshaft into crankcase with short end of shaft facing timing gear.

14. Put bearing housing so hole is in alignment with stud. Install stud and steel washer (Fig. 6–47). Tighten it according to tightening procedures.

15. Put thrustwasher on endshield.

Put grease on thrustwasher .

The tab of water will drop into recess in end shield (Fig.6–49).

16. Put oil on the crankshaft bearing and end shield.

PI–01993

Fig. 6–47 Positioning Bearing Housing

Dealer Copy -- Not for Resale

10. Install bolt and steel washers (Fig. 6–45). Tighten and lock down bolts according to fastener tightening instructions.

Refer to table for angles of turn to which screws should be tightened.

N–15921

Fig. 6–48 Positioning Thrust Washer

17. Install end shield, using a new gasket (Fig. 6–49).

18. Measure end clearance of crankshaft.

It must be .008–.016 inches (0,200–0,400 mm). When clearance is more, the end shield must be removed. Remove bolts, then withdraw end shield with puller (Fig. 6–50). Fit shims (.006 [0,150 mm thick]) under end shield for correct end clearance.

PI–01996

Fig. 6–49 Mounting the End Shield 129 of 216

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B–02202

Fig. 6–50 Pull the End Shield 600, 600D, 610, 611 Loader Service Manual

19. Install lube oil pump, put tube end and groove in bearing bore (Fig. 6–51).

20. Put oil pump so hole for locking screw is in alignment. Install and tighten bolt (Fig. 6–52).

21. Put on crankshaft gear wheel.

Tighten and lock down (Fig. 6–53).

23. Install camshaft. Install thrustwasher to front camshaft bearing (Fig. 6–55). Put oil on bearing areas. Install camshaft end in engine housing.

N–15922

Fig. 6–51 Install the Lube Oil Pump

N–15923

Fig. 6–52 Locking Pump in Place

NOTE: The camshaft gear wheel must be installed so tooth marked with a dot engages in groove marked with two dots on crankshaft gear wheel.

The other gap marked with two dots should be in direction of governor bearing bore (Fig. 6–56).

B–02199

24. Turn engine upside down while holding loose camshaft.

Fig. 6–53 Mount the Crankshaft Gearwheel

N–15924

Fig. 6–54 Installing Tappets

25. Install assembled centralfugal governor. Force governor shaft ball bearing into its seating position in engine housing.

Install governor shaft. Install retainer washer with its offset side facing the bearing. Install and tighten fastening screw (Fig. 6–57)

B–02198

NOTE: Make sure gears are correctly engaged. The tooth mark with a dot on governor and camshaft gear wheels must engage in same gaps marked with two dots on crankshaft gear wheel (Fig. 6–58). Put fly weights in guide plate and assemble governor dish (Fig. 6–59).

Fig. 6–55 Install Camshaft Thrust Washers

N–15925

Fig. 6–56 Correct Engagement

N–15926

Fig. 6–57 Install the Governor Shaft 130 of 216

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PI–01994

Fig. 6–58 Correct Engagement 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

22. Put oil on tappets and install in crankcase (Fig. 6–54).

Push governor plate in seat location and measure distance from front face of plate to wall (3–2/5 inch [85,7 mm]) (Fig. 6–60). When distance is not within correct rage, make correction with shims.

26. Install distributor housing for oil filter and turn it until locating tab engages in slot in engine housing (Fig. 6–61). Install compression spring for distributor housing in front cover assembly (Fig. 6–62).

PI–01995

Fig. 6–59 Assemble the Governor

N–15927

Fig. 6–60 Locate the Governor Dish

Check that two locating pins are installed into front caliper (Fig. 6–63).

28. Measure camshaft end clearance.

The correct dimension is .005–.024 inch (0,15–0,6 mm) (Fig. 6–64 & 6–65).

PI–01986

Fig. 6–61 Insert Distributor Housing for Oil Filter

Dealer Copy -- Not for Resale

27. Install anew gasket to front cover.

PI–01985

Fig. 6–62 Insert the Compression Spring

29. Install front cover assembly and fasten it with seventeen bolts (Fig. 6–66).

PI–01990

Fig. 6–63 Install the Locating Pins

PI–02057

Fig. 6–65 Camshaft End Clearance 131 of 216

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PI–01987

Fig. 6–64 Camshaft End Clearance

PI–02054

Fig. 6–66 Install the Front Cover 600, 600D, 610, 611 Loader Service Manual

NOTE: Check different lengths of bolts. The longest bolt should be installed in hole below oil filter location (Fig. 6–67).

30. Install V–belt sheave.

Check that heavy fastening sleeve for locating V–belt pulley is assembled (Fig. 6–68).

Put V–belt sheave in position and install tightening bolt with steel washer. Tighten and lock down bolt following tightening instructions (Fig. 6–69).

N–15928

Fig. 6–67 Longest Screw Location

N–15929

Fig. 6–68 Clamping Sleeve

Install fuel injection pump with ball head of control rod facing control lever and fasten.

Measure distance from top face of engine housing to the base circle of the cam.

(See SPECIFICATIONS.) Add gaskets when necessary (Fig. 6–71 & 6–72).

N–15930

Fig. 6–69 Installing The V–Belt Pulley

N–15931

Fig. 6–70 Aligning Fork with Recess

32. Push a new bearing bushing into flange bearing (Hydraulic pump drive) (Fig. 6–73).

Install a new seal ring with lip toward bushing and press itinto position by putting even pressure around circumference (Fig. 6–74). Install a new gasket to flange and use grease to hold it in position.

PI–02043

Fig. 6–71 Taking Measurement

N–15932

Fig. 6–72 Installing Injector Pump

N–15933

Fig. 6–73 Install Bushing and Seal 132 of 216

–6–10–

N–15934

Fig. 6–74 Install a New Gasket 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

31. Line fork of control lever with recess in engine housing (Fig. 6–70).

Install flange bearing with oil return hole at bottom. Install and tighten holding bolt (Fig. 6–75).

33. Install flywheel. Install fastening bolts with steel washers. Tighten 60° + 30° and lock the fastening bolts (Fig. 6–76).

N–15935

Fig. 6–75 Mount the Flange Bearing

N–15936

Fig. 6–76 Mount the Flywheel

35. Install piston onto connecting rod so tip of gas guiding channel in piston crown side of big end both face upward (Fig. 6–78).

PI–02053

Fig. 6–77 Assembling Piston Pin

Dealer Copy -- Not for Resale

34. Use snap rings when assembling piston pins into pistons (Fig. 6–77).

N–15937

Fig. 6–78 Mount Piston on Rod

Put oil on piston pin and push it into connecting rod busing so it is against installed snap ring (Fig. 6–79). Install other snap ring.

36. Put oil on working surfaces of cylinder. Make sure ring gaps are not in line on piston. Use a ring compressor (Deutz number 1–410–05) (Fig. 6–80).

N–15938

Fig. 6–79 Installing Piston Pin

N–15939

Fig. 6–80 Installing Piston

NOTE: Line piston with connecting rods so that low side of big end is toward side of cylinder barrel which has four not even cooling fins (Fig. 6–81).

37. Assemble .08 inches (20,2 mm) thick shims to each cylinder.

Put grease on shims to hold them in position (Fig. 6–82).

PI–02056

Fig. 6–81 Aligning Piston 133 of 216

–6–11–

N–15940

Fig. 6–82 Installing Shims 600, 600D, 610, 611 Loader Service Manual

38. Put grease on new rubber O–ring and install it in grooveat base of cylinder (Fig. 6–83).

39. Install bearing in connecting rod big end. Put oil on bearing.

NOTE: The correct size bearing must be used.

40. Position crankcase on starter side.

N–15941

Fig. 6–83 Installing O–ring

PI–02055

Fig. 6–84 Installing Cylinder Assembly

42. Put connecting rod with assembled bearing on crankpin (Fig. 6–85).

43. Assemble connecting rod cap with bearing. Check that identification numbers are in correct position (Fig. 6–86).

N–15942

Fig. 6–85 Place Rod End on Crankpin

N–15943

Fig. 6–86 Installing Connecting Rod Caps

NOTE: Use new connecting rod bolts. they must be tightened 30° + 60 ° and fastened down.

44. Install lower crankcase cover and check that oil plug is in correct position. The gasket for cover must be new (Fig. 6–87).

45. Put engine with cylinders vertical position.

in

N–15944

Fig. 6–87 Install Lower Crankcase Cover

PI–02064

Fig. 6–88 Cylinder Head Stud Length

46. Install cylinder head assembly and loosely install bolts (Fig. 6–88).

47. Cover the intake opening.

48. Make alignment of cylinder heads to flange faces for exhaust manifold (Fig. 6–89).

49. Tighten 30° + 60 ° + 60° and fasten down cylinder head studs from corner to corner (Fig. 6–90).

PI–02047

Fig. 6–89 Align the Cylinder Heads 134 of 216

–6–12–

N–15945

Fig. 6–90 Tightening Down Head Bolts 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

41. Install piston cylinder and connecting rod assembly in crankcase.

Check that connecting rods are assembled with identification numbers in correct position. The four not even fins of cylinder and low junction point of connecting rod must be toward tappet holes (Fig. 6–84).

50. Check width of gap between crown of piston and face of cylinder head.

When piston is in top dead center position, install a pieceof .078 inch (2 mm diameter) lead wire in opening for injection nozzle holder (Fig. 6–91). the lead wire must extend exactly across full diameter of piston (Fig. 6–92).

Remove lead wire and measure thickness at greatest compressed point. Correct distance from face of cylinder head to crown of piston is .035–.043 inches (.9–1.1 mm) (Fig. 6–93).

When distance is less than limits it must be corrected by placing shims between cylinder barrel and crankcase. A distance over maximum can be corrected by removing a shim without removing cylinder .

Remove only the cylinder head. the shim can then be cut through and removed (Fig. 6–94).

N–15946

Fig. 6–91 Inserting Lead Wire

N–15947

Fig. 6–92 Lead Wire

N–15948

Fig. 6–93 Gauging Lead Wire Thickness

Dealer Copy -- Not for Resale

51. Turn crankshaft through 360° of rotation.

N–15949

Fig. 6–94 Removing shim

52. Install new seals for protective tubes with beveled edges downward in crankcase.

Loosely install clamping plates (Fig. 6–91).

53. Install protective tubes fitting with new seals. the bevel edge of new seal must be toward bearing surface under head of protective tube (Fig. 6–96).

54. Tightening fastening plates that retains lower protective tube seal rings (Fig. 6–95).

PI–02037

Fig. 6–95 Install the Clamping Plates

55. Install push rods.

PI–02038

Fig. 6–96 Install the Protective Tubes

56. Loosen valve adjustment bolts in rocker arm assembly.

57. Install rocker.

58. Install a bearing busing for each rocker and install rocker .

Tighten bolt tight and fasten (Fig. 6–97).

59. Make valve adjustments.

clearance

60. Fasten cylinder head covers using a new packing and anew gasket (Fig. 6–98).

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N–15950

Fig. 6–97 Rocker Screws –6–13–

N–15951

Fig. 6–98 Attach Cylinder Head Cover 600, 600D, 610, 611 Loader Service Manual

61. With a brush apply graphite grease to nozzle holder threads. Turn nozzle holder , fitted with a new gasket, finger tight in cylinder head. It must not be fastened down until fuel injection lines have been connected (Fig. 6–99).

62. With a brush cover threads of heater plug with a graphite grease. Turn in heater plug.

Connect electric supply wire (Fig. 6–100).

N–15952

Fig. 6–99 Loosely Fit Nozzle Holders

N–15953

Fig. 6–100 Screw in the Heater Plug

63. Install induction line, using new gasket (Fig. 6–101).

64. Fasten baffle between cylinders on exhaust side (Fig. 6–103).

65. Install new gaskets for exhaust manifolds and install manifolds.

The holddown nuts must be brass and washers must be used (Fig. 6–104).

N–15954

Fig. 6–101 Installing the Induction Pipe

N–15955

Fig. 6–102 Securing Induction Pipe

66. Install end plates next to cylinders (Fig. 6–105).

67. Install cooling air blower and fasten with three bolts (Fig. 6–106).

N–15956

Fig. 6–103 Installing Baffle

N–15957

Fig. 6–104 Install Manifold

N–15958

Fig. 6–105 Install the End Plates 136 of 216

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PI–02051

Fig. 6–106 Mount the Blower 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

Fasten induction line on first cylinder with a single, groove bolt (Fig. 6–102).

68. Install generator.

The sleeve for installing generator must be installedwith shoulder end in the cooling air blower(Fig. 6–107).

Install generator and install shims to close gaps between sleeves and grooved arm of generator.

Fig. 6–107 Install Spacer Sleeve

N–15960

Fig. 6–108 Check V–Belt Pulley Alignment

for

Correct any alignment by changing over shims between generator and bearing points on cooling air blower (Fig. 6–109).

Check that bushing is in place before installing bolts in grooved adjustment straps (Fig. 6–110). To install other type generator see (Fig. 6–111).

N–15961

Fig. 6–109 Spacing Shims

N–15962

Fig. 6–110 Installing Spacer and Screw

1 Correct belt tension is about 5/8 inch (15 mm) play on the longest belt length (Fig. 6–112).

69. Fasten fuel filter to crankcase on flywheel side (Fig. 6–113).

Dealer Copy -- Not for Resale

Check V–belt sheave alignment (Fig. 6–108).

N–15959

2 B–01246

Fig. 6–111 Alternator Mounting

N–15963

Fig. 6–112 Belt Tension 137 of 216

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N–15964

Fig. 6–113 Attaching Fuel Filter 600, 600D, 610, 611 Loader Service Manual

70. Install fuel line between delivery filter and injection pump. Use new gasket on both sides of special fitting (Fig. 6–114).

71. Use clip to fasten fuel line to front cover (Fig. 6–115).

72. Make correct adjustment of delivery of injection pump (See page 6–3).

N–15965

Fig. 6–114 Install the Fuel Line

Fig. 6–115 Secure the Fuel Line

74. Fasten fuel injection line clip above cooling air blower. Make sure vibration rubbers are in good condition.

N–15967

Fig. 6–116 Lock Down the Union Nuts

N–16046

Fig. 6–117 Tighten the Nozzle Holder

NOTE: The fuel injection lines must be installed so they are clear of all wear areas.

75. Tighten nozzle holder using a wrench (Deutz number 4605) (Fig. 6–117).

76. Install leak–off line. Install a new gasket on both sides of special fittings (Fig. 6–118).

Put oil cooler through end plate on flywheel side (Fig. 6–119).

N–15968

Fig. 6–118 Install the Leak–Off Pipe

N–15969

Fig. 6–119 Install the Oil Cooler

Put a hollow bolt in each end of tubular oil cooler. Install a new gasket on each side of special fittings (Fig. 6–120). Slip two holders for oil cooler on cylinder head studs. Check that they are correctly located (Fig. 6–121).

N–15970

Fig. 6–120 Securing Cooler Ends 138 of 216

–6–16–

N–15971

Fig. 6–121 Oil Cooler Holders 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

73. Install fuel injection lines. The tapered ends must first be in place and union nuts tightened by hand. Check that tapered ends are correctly in seat.

Fasten down union nuts (Fig. 6–116)

N–15966

Fasten oil cooler to holders.

Check that they are clear of wear areas (Fig. 6–122).

77. Install air housing and fasten it in position (Fig. 6–123).

NOTE: Check that fuel injection lines are clear of housing.

78. Install starter (Fig. 6–124).

79. Fill crankcase to proper level with correct grade of motor oil.

6–5 INSPECTION AND REPAIR

PI–02050

Fig. 6–122 Secure the Oil Cooler

N–15972

Fig. 6–123 Mount the Air Housing

6–5.1 Checking The Crankshaft 1. Disassemble bearing housing.

crankshaft

3. Test journal surfaces for hardness with a scleroscope (Fig. 6–125).

4. Measure crankshaft points for tolerances as in (Fig. 6–126 & 6–127).

Check for out–of–round with a dial indicator gauge (Fig. 6–128).

N–15973

Fig. 6–124 Attach the Starter

Dealer Copy -- Not for Resale

2. Check crankshaft for cracks. If any are found, install new crankshaft.

N–15974

Fig. 6–125 Test the Journal Hardness

5. Check working surfaces for radial seal ring on journal at flywheel end to determine if it is good.

6–5.2 Reconditioning Crankshaft NOTE: Mark and remove crankshaft counterweights when assembly uses same type of bolts and steel washers. Tighten and fasten down bolts.

N–15975

Fig. 6–126 Measuring Points

N–15976

Fig. 6–127 Micrometer Readings

1. Grinding The crankshaft bearings can be taken down to .020, .040 (5,80,10,16 mm) undersize.

6–5.3 Checking Crankcase 1. Check crankcase that it is clean. Check lubrication oil ways which can be cleaned out with air.

2. Inspect crankcase for cracks (Fig. 6–129).

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N–15977

N–15978

Fig. 6–128 Check Bearings for Out–Of–Round

Fig. 6–129 Inspecting Crankcase for Cracks

–6–17–

600, 600D, 610, 611 Loader Service Manual

3. Clean all tapped holes (Fig. 6–130).

4. Check main bearing bores. The bearing bushings fitted for crankshaft and camshaft must be seated. The unlined bores must be free of wear (Fig. 6–131).

5. Check contact surfaces for cylinders. They must be flat and free from damage (Fig. 6–132).

NOTE: Contacting surfaces can be machined.

6–5.4 Checking And Main Bearing

Installing

N–15979

Fig. 6–130 Clean All Tapped Holes

N–15980

Fig. 6–131 Check Bearing Bores

Main bearing are of thin type. Do not recondition them. V arious diameter bushings and housing that are supplied are .020, .040 (5,08, 10,16 mm).

2. Check bore of lower half of crankshaft bearing.

Bolt cap to lower half of bearing.

Make sure identification marks are correct. Tighten 30° + 60° and fasten down bolts (Fig. 6–134).

N–15981

Fig. 6–132 Check Cylinder Contact Surface

N–15982

Fig. 6–133 Bolt Cap to Bearing

3. Measure assembled bearing housing.

Install two shelf halves (Fig. 6–134). Check assembly.

Check tolerance of bearings.

When measurements are within specific tolerance range or up to 0,2 mm (.007 inches) beyond it, the bearing housing can be used.

4. Install measured bearing halves in correct housing.

Remove bearing bushings requiring replacement and install new ones (use tool, Deutz number 4679).

N–15983

Fig. 6–134 Install Two Shell Halves

Fig. 6–135 Extracting Bearing Bushings

Fig. 6–136 Mount the Extractor Ball

Fig. 6–137 Oilhole Alignment

To remove bearing bushings from crankcase, fasten the tool with pressure plate and full length tension bolt togetherwith guide sleeve and thrust sleeve (Fig. 6–135). Install (from outside) the extractor bell with handle in nut (Fig. 6–136).

Remove bearing bushing.

When installing bearing bushing, check that oil hole is correct position with crankcase bore (Fig. 6–137).

140 of 216

PI–02066

–6–18–

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

1. Measure bearing bushings fitted into crankcase and back end cover.

Install bearing bushing. Put iton guide sleeve of tool in front of pressure plate. The thrust sleeve then has to fit bushing into crankcase bore (Fig. 6–138).

Install bearing housing so that it extends out of crankcase surface (See Specifications, page 6–33) (Fig. 6–138).

5. Use driver to force out seal rings before removing bearing bushing from rear end cover (Fig. 6–139).

PI–02066

Fig. 6–138 Install Bearing into Crankcase

7. Put seal with lip facing bearing, use even pressure around circumference.

6–5.5 Checking and Installing Camshaft and Bearings 1. Inspect camshaft, check bearing and cam faces. Check camshaft gear wheel for tooth wear and cracks.

N–15984

Fig. 6–139 Drive Out Seal Ring

N–15985

Fig. 6–140 Installing Bearing Bushing

2. Inspect bearing bores and crankcase. Check bore of bearing of bearing liner of gear wheel side.

Check bore of bearing bushing at minimum of two points in horizontal and vertical position (Fig. 6–141).

3. Push out bearing bushing that is to be replaced and install a new one, using special tool Deutz number 1–410–06 (driver for camshaft bearing bushing).

N–15986

Fig. 6–141 Gauging Bore

Dealer Copy -- Not for Resale

6. When installing bearing bushing check oil hole for correct position with end shield bore. Install bearing bushing so that outer end (seal ring) iseven with end of cover bore (Fig. 6–140).

N–15987

Fig. 6–142 Force Bushing Inward

To remove bearing bushing without using a guide bushing, put bushing under a press, with driver, from outside bushing, pushing in (Fig. 6–142).

For installation of new bearing bushing fasten guide bushing on bar. Put bearing bushing in position and push in. Check spacing of lubricating oil holes in bearing bushing. The short spacing must face out. When bushing is pushed into position it must be even with top surface and oil holes must be in alignment with those in bearing bore (Fig. 6–143).

141 of 216

PI–02049

Fig. 6–143 Insert Bearing Bushing –6–19–

N–15988

Fig. 6–144 Insert Closure 600, 600D, 610, 611 Loader Service Manual

4. Check that closure for camshaft bore is assembled and that its seat is tight. When new closure is to be installed, the old one must be driven out. Use a sealing material.

Install and force it in with tool Deutz number 131.018 (Fig. 6–144).

6–5.6 Checking The Oil Pump End play of pump gear is a measure of wear of gear type lubricating oil pump.

Do not disassemble pump.

1. Put lubricating oil pump in a vise with driving gear up. The vise should have protective jaws and be lightly tightened on pump.

N–15989

Fig. 6–145 Checking End Play

PI–02042

Fig. 6–146 Cutting Starter Ring

2. Install a dial indicator with a magnetic base and check endplay of driving spindle (Fig. 6–145).

1. Check gear starter ring.

2. To remove starter ring, cut it with a hand chisel (Fig. 6–146).

N–15990

3. Heat new starter ring to 200°C, then install.

about

Fig. 6–147 Inspect Front Cover

N–15991

Fig. 6–148 Dismantling Engine Governor

6–5.8 Checking Front cover And Repair Of Engine Governor 1. Remove all loose parts from front cover.

2. Inspect front cover and parts of engine governor (Fig. 6–147).

3. To disassemble engine governor , use driver to force out heavy duty fastening sleeve and pull speed control lever from control spindle.

N–15992 Loosen leaf spring from spindle Fig. 6–149 Remove Snap Ring and remove snap rings on side of control lever. Pull control spindle from front cover and remove control lever, seal spring and leaf spring (Fig. 6–148).

N–15993

Fig. 6–150 Insert the Bushing

4. Remove snap ring from bearing pin for fuel lock. Pull stop lever and torsion spring (Fig. 6–149).

5. Remove grommets from fuel pressure pins and pull pressure pins. Check pressure pin and bushing and replace when bad. When bushing is pressed in position it must project between 0,5 and 1 mm (.0196 inches to .0393 inches) beyond flange face on front cover . Install bushing so 15° internal level is at extended end (Fig. 6–150). Use tool for valve guide, Deutz number 1–812–13.

6. Pry out sealing ring for governor bearing and replace it with a new one (Fig. 6–151).

PI–02045

Fig. 6–151 Pry Out Sealing Ring 142 of 216

–6–20–

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

6–5.7 Installing A New Gear Starter Ring On Flywheel

7. Check needle bearing and replace it with a new one when bad. The needle bearing must be forced out and a new one installed using a tool for piston pin bushing, Deutz number 1–310–13 (Fig. 6–152).

8. Install new sealing ring with lip facing in and press it all around until it is evenly in position.

PI–02046

Fig. 6–152 Install Needle Bearing

N–15994

Fig. 6–153 Check the Closure

9. Check that closure of bore is in alignment with camshaft bearing seats and is oil tight.

Replace it with a new one when bad (Fig. 6–153).

11. Remove threaded bushings from the adjustment screw pin for stop lever (blocking system) (Fig. 6–155).

Dealer Copy -- Not for Resale

10. Put new gaskets under allplugs (Fig. 6–154).

PI–02040

N–15995

Fig. 6–154 Install New Gaskets Under Plugs.

Fig. 6–155 Remove Threaded Bushing

12. Remove lock nuts.

Turn threaded pin in and remove (Fig. 6–156).

13. Install governor in control position. Turn in threaded pin.

Assemble lock nut with sealing ring. When lock nut is tight the threaded end of pin must be extended about (.4724 inch) 12 mm (Fig. 6–157).

N–15996

Fig. 6–156 Remove Lock Nuts

N–15997

Fig. 6–157 Install Governor

14. Install threaded bushing. Make nut seat against lock nut by fitting rings between two faces of nuts (Fig. 6–158).

15. Check full load stop screw for speed control lever. Install stop screw complete with a (.12 inch) 3 mm steel washer (Fig. 6–159).

N–15998

Fig. 6–158 Install Screwed Bushing 143 of 216

–6–21–

N–15999

Fig. 6–159 Install Stop Screw 600, 600D, 610, 611 Loader Service Manual

16. Check no load adjustment screw set in position. Tighten adjustment screw with a lock nut so that distance of top of lug to top face of screw is about (1.18 inch) 30 mm (Fig. 6–160).

17. Put grease in middle groove of priming pressure pin and assemble pin. Install a new rubber sealing ring in lower groove (Fig. 6–161).

18. Install torsion spring with long offset end down, so that it is in location over bearing pin. Put fuel lock with release lug down (Fig. 6–162).

N–16000

PI–02071

Fig. 6–160 Check No–Load Adjusting Screw

Fig. 6–161 Installing Rubber Sealing Ring

20. Install speed control spindle with flat end from control lever side and install thrust washer (Fig. 6–164). a. Slide spindle fully through and install snap ring in groove near speed control lever.

PI–02072

Fig. 6–162 Install Torsion Spring

N–16001

Fig. 6–163 Install Snap Ring

b. Slide speed control lever on spindle and put in heavy duty fastening sleeve. c. Measure end clearance.

Disassemble fitting snap ring and speed control lever . Push back spindle and when needed install a shim.

PI–02003

Fig. 6–164 Install Speed Control Spindle

PI–01999

Fig. 6–165 Mount Control Lever

21. Install control lever and push speed control spindle in further (Fig. 6–165).

22. Install control lever seal spring so that short end locates between two cast dots on cover and long end is positioned behind arm on control lever (Fig. 6–166).

23. Install control leaf spring. Move speed control spindle farther in and fasten control fork (Fig. 6–167).

PI–02000

Fig. 6–166 Installing Seal Spring 144 of 216

–6–22–

PI–02001

Fig. 6–167 Installing Control Leak Spring 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

19. Turn fuel lock through 270 ° counterclockwise (For initial testing of spring) and push it down so that release lever locates under pin. Install snap ring (Fig. 6–163).

24. Install snap rings on either side of control lever on speedcontrol spindle (Fig. 6–168).

25. Check speed control lever .

Check for free movement of full load adjustment screw and that leaf spring for no load and stop position is in correct order. Put in basic position. When lock nut is tightened the thread of adjustment screw must have extension of about (.354 inch) 9 mm (Fig. 6–169).

PI–02002

Fig. 6–168 Inserting Snap Ring

N–16002

Fig. 6–169 Checking Speed Control Lever

26. Slide rubber sealing rings into groove in bearing bore (Fig. 6–170).

6–5.9 Check and repair Of the Governor 1. Inspect governor dish. Check thrust and needle bearings and disassemble when needed. To disassemble thrust bearing force out snap ring and remove loose bearing parts.

PI–02032

Fig. 6–170 Installing Rubber Sealing

Rings

Dealer Copy -- Not for Resale

27. Check that a plug is fitted on opposite sides (Fig. 6–171).

Install one when necessary.

Check engine governor to make sure that it functions smoothly.

N–16003

Fig. 6–171 Check for Plug

2. Assemble thrust bearing for installation. Hold twenty–one balls in position with grease (Fig. 6–172).

3. Install assembled thrust bearings together with shims which were removed. The bent tabs must be toward the bearings and center shims(Fig. 6–173).

PI–02008

Fig. 6–172 Assemble Thrust Bearing

PI–02009

Fig. 6–173 Install Thrust Bearing

NOTE: When installing governor check final thickness of shims and correct when needed.

4. Install snap ring and check end clearance of thrust bearing (Fig. 6–174).

5. Check needle bearing and when needed, install new. Push out old bearing and install new one so that its location is even with end face (Fig. 6–175).

PI–02010

Fig. 6–174 Insert Snap Ring 145 of 216

–6–23–

N–16004

Fig. 6–175 Check Needle Bearing 600, 600D, 610, 611 Loader Service Manual

6. Remove bolt fastening ball bearing to end of governor spindle and remove retaining washer (Fig. 6–176).

7. Remove ball bearing from governor spindle (Fig. 6–177).

8. Check ball bearing. When not in new condition, install a new one.

NOTE: When assembling ball bearing, do not fasten it to governor spindle. Position it in crankcase.

N–16005

Fig. 6–176 Remove Retaining Washer

N–16006

Fig. 6–177 Remove Ball Bearing

10. Inspect flyweights. Check that they are fastened. A bad flyweight must have replacement with new (Fig. 6–179).

6–5.10 Checking And Replacement Of Connecting Rod Bearings The big end bearings are of non–adjustable thin type. Do not machine or recondition them. The two bearing halves are supplied in sizes to match crankshaft undersizes of .020, 040 (5.08, 10.16 mm).

N–16007

N–16008

Fig. 6–178 Replacing Holder Ring

Fig. 6–179 Inspect Flyweights

Fig. 6–180 Bearing Wall Thickness

Fig. 6–181 Press out Piston Pin

1. Remove bearings. Refer to Specifications for wall thickness (Fig. 6–180).

2. To remove piston from connecting rod, remove both snap rings and press out piston pins (Fig. 6–181).

3. Check bearing bore.

N–16010

Assemble cap to connecting rod.

Check that they have same identification number (Fig. 6–182).

Bolt cap to connecting rod. Tighten to 30° + 60° and lock down bolts (Fig. 6–183). Use micrometer and set internal dial indicator to (2.2444 inch) 57 mm.

N–16011

Fig. 6–182 Assembling Cap to Rod 146 of 216

–6–24–

N–16012

Fig. 6–183 Lock Down the Bolts 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

9. Inspect flyweight holing ring for wear. When flyweight grooves have damage, install older rings with a new one (Fig. 6–178).

Check the bore at various position (Fig. 6–184).

diagonal

NOTE: When new bearings are needed, follow above steps to check bearing clearances.

6–5.11 Checking And Replacement Of Piston Pin Bushing 1. Check bore of piston pin bushing.

Check bore of piston pin bushing at several diagonal positions(Fig. 6–185).

N–16013

Fig. 6–184 Gauge the Bore

N–16014

Fig. 6–185 Gauge the Piston Pin Bore

2. To remove a piston pin bushing, push it out with tool, Deutz number 1–310–13. When installing a new bushing, make sure that it is located in center of little end of connecting rod. The oil holes must be in correct position (Fig. 6–186).

NOTE: When installing a connecting rod, first check it in a checking alignment fixture to determine if bores are square and in alignment.

The bearings must be included. Measure at a distance of (3.937 inches) 100 mm from rod face, pin installed in small end must not be more than (.003 inch) 0,008 mm out of alignment (Fig. 6–187).

N–16015

Fig. 6–186 Pressing in Piston Pin Bushing

N–16016

Fig. 6–187 Checking Bore Alignment

1 2 3

6–5.12 Checking Cylinders NOTE: A standard size cylinder can be cut to larger sizes .020 or .040 inch (5,08, 10,16 mm) only.

Dealer Copy -- Not for Resale

NOTE: When reading is above specified tolerance by more than (.0078 inch) 0,22 mm, piston pin bushing must have replacement by a new one.

4

PI–02016

Fig. 6–188 Measure Working Surface

a

b

Fig. 6–189 Gauging Points

1. Using a micrometer with internal dial gauge set to size of bore (Fig.6–188).

2. Measure working surface of cylinder bore (Fig. 6–189).

3. Check top and bottom contact surfaces of cylinder to make sure they are flat.

6–5.13 Checking And Measuring Pistons NOTE: Pistons are available in three diameters to match the corresponding undersize of the cylinders.

1. Use a plier to measure the diameter of piston. Size is stamped on crown of piston (Fig. 6–190).

N–16018

Fig. 6–190 Piston Diameter Marking 147 of 216

–6–25–

600, 600D, 610, 611 Loader Service Manual

2. Remove piston rings with an expander tool (Fig. 6–191).

1 2

3. Clean piston and inspect for visual damage and wear.

Check the piston bosses and ring groove (Fig. 6–192).

3 4

4. Measure vertical clearance of rings and grooves (Fig. 6–193).

5. Install piston rings individually in respective cylinders and use a piston to press them down to a depth of about (1.2 inch) 30 mm. Measure the gapClarence (Fig. 6–194).

Fig. 6–191 Removing Piston Rings

Fig. 6–192 Inspect the Piston

wear

NOTE: When piston pin bosses or piston pins are not up to standard complete piston must have replacement made. Piston pins must always be installed in same original pistons.

Use an expander tool for installing piston rings. The identification marks on rings must face upward. In case of conformable oil rings, the spiral springs must first be individually fitted (Fig. 6–196).

N–16021

Fig. 6–193 Ring Vertical Clearance

PI–02048

Fig. 6–194 Measuring Ring End Clearance

NOTE: Install piston rings in following order: (Fig. 6–197).

Grooved 4. Single land beveled conformable oil control ring.

Grooved 3.

Stepped compression ring Grooved 2.

Stepped compression ring.

Grooved 1. T compression (Chromium plated).

N–16022

Fig. 6–195 Inspect Piston Pins

N–16023

Fig. 6–196 Install Rings

op ring

6–5.14 Repair Of Cylinder Head 1. Fasten cylinder head in swivel stand (Fig. 6–198).

N–16024

Fig. 6–197 Ring Positions 148 of 216

–6–26–

N–16025

Fig. 6–198 Mount Cylinder Head in Stand 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

6. Inspect piston pins for (Fig. 6–195).

N–16019

2. Remove tightening screw of rocker fastener (Fig. 6–199).

3. To remove rocker, pull bearing bushing from one side (Fig. 6–200).

4. Remove loose push rods protective tubes from cylinder head top.

PI–02011

PI–02012

Fig. 6–199 Remove Rocker Mounting Screw

Fig. 6–200 Withdraw Bearing Bushings

5. Remove valves and valve springs (use valve compressor, Deutz number 1–310–01) (Fig. 6–201).

6. Remove top of cylinder head.

8. Check cylinder head contacting surface. It must be flat and square. It can be faced new if the distance from the face to bottom of cylinder head iswithin tolerance (Fig. 6–202).

PI–02013

Fig. 6–201 Removing Valves

N–16026

Fig. 6–202 Checking Cylinder Head

9. Small damage to cylinder head contacting surfaces can be removed by grinding with fine paste put on cylinder barrel.

When surface has more damage, it must be faced new with cutter tool, Deutz number 1–410–03 (Fig. 6–203).

10. Recondition valve seating rings that are not to be installed new.

Use valve seating tool, Deutz number 1–310–08 (Fig. 6–204).

PI–01982

Fig. 6–203 Refacing Cylinder Head Surface

Dealer Copy -- Not for Resale

7. Inspect cylinder head for cracks and external damage.

N–16027

Fig. 6–204 Using Valve Re–seater

11. Install new valves. Measure distance from valve head to bottom of cylinder head (Fig. 6–205).

12. To install a valve seating ring proceed as follows: a. Drill to bottom of valve seating ring, without damaging light metal collar (Fig. 6–206).

PI–01984

Fig. 6–205 Measuring Valve Head Clearance 149 of 216

–6–27–

PI–02030

Fig. 6–206 Drill to Bottom of Ring 600, 600D, 610, 611 Loader Service Manual

b. Use a hard chisel at an angle of 90° to the drilled seating ring. Hit chisel and pry out loosened ring (Fig. 6–207). c.

Heat cylinder head in a heating cabinet or furnace to a temperature of about 250°C. Put new valve seating ring, beveled side first, on driver tool and force ring in until hits bottom (Fig. 6–208).

NOTE: The valve seating ring must be square in seat on bottom.

PI–02031

Fig. 6–207 Removing Old Ring

N–16028

Fig. 6–208 Driving in New Ring

14. When it is necessary to make replacement of a valve guide, proceed as follows: a. Heat cylinder head in a heating cabinet or furnace to about 150°C. Use tool, Deutz number 1–812–03, to force out valve guide from the seating ring side (Fig. 6–210).

PI–02058

Fig. 6–209 Valve Stem Clearance

PI–02004

Fig. 6–210 Drive Out the valve Guide

b. Remove snap rings from old valve guide and install it on new guide. c. With cylinder head heated to 250°C., use driver to force longer end of valve guide from rocker arm support side until it is inseat on fastening wire (Fig. 6–211).

PI–02005

Fig. 6–211 Driving in Valve Guide

PI–02006

Fig. 6–212 Ream Valve Guide Bore

d. Use reaming tool to bore valve guide after cylinder head has become cold (Fig. 6–212).

15. Install steel washers for cylinder head studs (Fig. 6–213).

16. Install top element of cylinder head and fasten it with four studs (Fig. 6–214).

PI–02007

Fig. 6–213 Insert Steel Washers 150 of 216

–6–28–

PI–02017

Fig. 6–214 Mount Cylinder Head 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

13. The valve stem clearance must be measured just above valve guide. Install a valve and move it sideways in guide (Fig. 6–209).

17. Install a new rubber O–ring in valve spring retainer to the valve guide (Fig. 6–215).

18. Measure length of valvesprings for tolerance (Fig. 6–216).

19. To install valve, assemble individual valve springs with spring retainer, compress the valve spring and install the collets (Fig. 6–217).

PI–02018

Fig. 6–215 Install New Rubber O–ring

PI–02019

Fig. 6–216 Measure Length of Valve Springs

6–5.15 Repair Of Rocker Arms 1. Check rocker arms and make replacement of worn parts.

6–5.16 Repair Of Cooling Air Blower

Dealer Copy -- Not for Resale

NOTE: When installing bearing bushing make sure oil holes are in correct position. The second hole in bushing must face up in rocker arm (Fig. 6–218).

PI–02020

Fig. 6–217 Installing Valves

PI–01997

Fig. 6–218 Replacing Rocker Arm Bushing

1. Remove fastening bolt and remove fan.

2. Use soft metal bar to force out bearing spindle (Fig. 6–219).

3. Remove grooved ball bearing from spindle (Fig. 6–220).

4. Remove snap ring in front of second groove ball bearing.

Use driver to force groove ball bearing out of blower casing.

PI–02061

Fig. 6–219 Drive Out Bearing Spindle

N–16030

Fig. 6–220 Remove Grooved Ball Bearing

5. Make replacement of both groove ball bearings with new ones and fill them with high melting point grease.

6. Press in small groove ball bearing with closed side facing down (Fig. 6–221).

7. Put snap ring in groove in front of installed groove ball bearing (Fig. 6–222).

PI–02035

Fig. 6–221 Press in the Ball Bearing 151 of 216

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PI–02036

Fig. 6–222 Install Snap Ring 600, 600D, 610, 611 Loader Service Manual

8. Push large groove ball bearing on spindle with closed side facing belt pulley (Fig. 6–223).

9. Push spindle with bearing into seat location in housing (Fig. 6–224).

10. Inspect fan to makesure it does not have damage.

11. Install the fan (Fig. 6–225).

N–16031

Fig. 6–223 Install Large Ball Bearing

N–16032

Fig. 6–224 Press in Spindle

6–5.17 Removing And Installing A Fuel Injection Nozzle 1. Turn out the union nut on nozzle holder. Remove the parts in nozzle holder (Fig. 6–227).

PI–02073

Fig. 6–225 Mount Impeller

PI–02029

Fig. 6–226 Secure Blower

2. Remove high pressure pipe union. Remove orifice plate.

3. Thoroughly clean all parts with clean diesel fuel. With an air jet blow out high pressure filter and feed pipe union from the thick end (Fig. 6–228).

4. Inspect components.

The nozzle needle is a near tight fit in nozzle body and parts must not be mixed. Do not touch the finished surfaces.

New nozzles must be washed in diesel fuel to remove rust and old grease. A good needlemust slide down slowly and smoothly into its seat when put into vertical held nozzle (Fig. 6–229). Put inspection clean components on a piece ofclean rag until ready to be installed.

N–16033

Fig. 6–227 Disassemble Nozzle Holders

5. Put orifice plate in nozzle holder and connect high pressure pipe union (Fig. 6–230).

N–16035

Fig. 6–229 Free Movement of Needle 152 of 216

N–16034

Fig. 6–228 Clean all Parts

–6–30–

N–16036

Fig. 6–230 Insert Orifice Plate 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

12. Fasten blower in position. Put blower and belt pulley in a vise.

Tighten bolt (Fig. 6–226).

6. Install shims (Fig. 6–231).

7. Install compression ring and thrust pin (Fig. 6–232).

8. Assemble fastening nut to nozzle holder (Fig. 6–233).

9. Install bushing and nozzle making sure that they are in center location (Fig. 6–234).

10. First tighten union nuts finger tight, then tighten to (40–50 ft.–lbs.) 5.57 M/kgF. 11. Check nozzle and make adjustment.

N–16037

Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . .

Cylinder Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical ... (in line) Cylinder Bore (F2L410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.54 . . (90) Cylinder Bore (F2L411) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.622 . . (92) Piston Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.94 . . . (100) ..

Total Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1272 cm3 (77.6 cu. in.)

Working Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . .stroke . diesel Direction of Rotation . . . . . . . . . . . . . . . . . . . . Counterclockwise .

(Flywheel end) Maximum Permissible Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2700 . . RPM Lowest Speed Under Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1500 . . RPM Lowest Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 . . . ±50 RPM Governed Flywheel Horsepower . . . . . . . . . . . . . . . . . . . . . . . . 24 . @ 2700 RPM Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–1 ....

Inlet Valve Opening Angle Before TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34° ..

Inlet Valve Closing angle After BDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60.5° .

Exhaust Valve Opening Angle Before BDC . . . . . . . . . . . . . . . . . . . . . . . . . 79.5° .

Exhaust Valve Closing Angle After TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° ..

Weight of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 . . kg (322 lb.)

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure ...

Air Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axial–flow ...

Blower Overall Dimensions of Engine Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541 . . . .(21.3) Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510 . . . .(20.08) Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 676 . . . .(26.6)

N–16038

Fig. 6–232 Install compression Spring

6–7 Torque Specifications (Deutz Engine) ITEM

PRELOADING

TIGHTENING

TOTAL

Cylinder Head Bolts

21.5 ft.–lbs. (29 Nm)

30° 60° 60°

150°

Injector Hold–Down

21.5 ft.–lbs. (29 Nm)

60° 60°

120°

Connecting Rod

21.5 ft.–lbs. (29 Nm)

30° 60°

90°

Camshaft Bearing Flange Bearing Support

25 ft.–lbs. (34 Nm) 21.5 ft.–lbs. (29 Nm)

30° 30°

Blower Mounting Bolts V–Belt Pulley

21.5 ft.–lbs. (29 Nm)

60°

90°

90° 11 ft.–lbs. (15 Nm)

21.5 ft.–lbs. (29 Nm)

30° 30°

Oil Suction Pipe

60° 36 ft.–lbs. (49 Nm)

Flywheel

21.5 ft.–lbs. (29 Nm)

60° 30°

90°

Rocker Arm Bolts

21.5 ft.–lbs. (29 Nm)

45°

45°

Balance Weight

21.5 ft.–lbs. (29 Nm)

30° 30°

60°

Alternator Pulley Nuts

40–60 (54–81)

153 of 216

N–16039

Fig. 6–233 Install Securing Nut

25 ft.–lbs. (34 Nm)

Intake Manifold Crankshaft Gear

Dealer Copy -- Not for Resale

Fig. 6–231 Reinsert Shims

6–6 GENERAL ENGINE DATA (F2L410)

N–16040

Fig. 6–234 Install Spacer and Nozzle –6–31–

600, 600D, 610, 611 Loader Service Manual

6–8 FITS, CLEARANCES, ADJUSTMENTS – DEUTZ ENGINE 6–8.1 Oil System Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . .28.5 .

PSI (196,6 kPa) @ 1500 RPM Capacity of system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. quarts .

(4 L) End Clearance in Oil Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . .004 . . (,1 mm) 6–8.2 Fuel System Pressure of Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . 4–5 .

PSI (27,5–34,5 kPa) Make of Fuel Injections Pump . . . . . . . . . . . . . . . . . . . . .Bosch .

PF 2K70A414/2 Make of Fuel Injection Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . DLLA ..

152 S 533 Release Pressure of Injection Nozzle . . . . . . . . . . . . . . . .New–2560–2675 PSI (17,650–18,450 kPa) Old–2490–2600 PSI (17,170–17,925 kPa) Injections timing (Start of Injection) . . . . . . . . . . . . . . . . . . . . . . . . .25° . B.T.D.C. Distance from Injection Pump Mounting Flange to Camshaft (Including gasket and shims) . . . . . . . . . . . . . . . . 3.248–3.256 .

(82,5–82,7 mm) 6–8.3 Governor, Front Cover and Throttle Distance from governor Bearing Cup to Engine Block . . 3.37–3.38 (85,6–85,7) End Play in Throttle Shaft . . . . . . . . . . . . . . . . . . . . . . . ..008–.043 . (,2–1,1 mm) Engine High Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2575 . . . RPM Engine Low Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 . . . RPM

Dealer Copy -- Not for Resale

6–8.4 Cylinder Head and Valves I.D. of Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . ..315–3155 .

(8.8,015 mm) I.D. of Bore for Exhaust Valve Seat . . . . . . . . . . . . .1.5354–1.5364 (39–39,025) I.D. of Bore for Intake Valve Seat . . . . . . . . . . . . . . . .1.378–1.379 (35,–39,025) Valve Seat Width, Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .040–.055 ..

(1,–1,4) Valve Seat Width, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . .031–.033 ..

(8,–,83) Valve Seat Angle, Exhaust and Intake . . . . . . . . . . . . . . . . . . . . . . . . . . .44–1/2° .

Valve Stem Diameter, Intake . . . . . . . . . . . . . . . . . . . . ..3134–.314 (7,96–7,975) Valve Stem Diameter, Exhaust . . . . . . . . . . . . . . . . . . ..3118–.3126 .

(7,92–7,94) Maximum Distance Valves may be Recessed into Head . . . . . . . . .020 (,5 mm) Maximum Distance Valves may Protrude from Head, Intake . . . . . . . .083 (2,11) Maximum Distance Valves may Protrude from Head, Exhaust . . . . . .095 (2,42) Valve Clearance, Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 . . . (,15 mm) Maximum Length of Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . .9.114 .

(231,5) 6–8.5 Cylinder and Piston Cylinder Bore (standard) . . . . . . . . . . . . . . . . . . . . . . .3.622–3.623 .

(92–92,022) Maximum Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .012 . . . (,3 mm) Piston Diameter (standard) . . . . . . . . . . . . . . . . 3.6197–3.620 .

(91,940–91,949) Piston Diameter (1st oversize) . . . . . . . . . . . . .3.6394–3.6397 (92,440–92,449) Piston Diameter (2nd oversize) . . . . . . . . . . . . . .3.659–3.6594 (92,940–92,949) Wrist Pin Bore . . . . . . . . . . . . . . . . . . . . . . . . . 1.1812–1.1814 ..

(30,002–30,007) Wrist Pin Diameter . . . . . . . . . . . . . . . . . . . . . .1.1809–1.1811 .

(29,996–30,000) Piston Ring Side Clearance, Compression Rings . . . . . . . . . . . . . . . . . .012 . (,3) Piston Ring Side Clearance, Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . .006 . . (,15) Ring End Gap, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . .014–.022 .. (,35–,55 mm) Ring End Gap, 2nd & 3rd Rings . . . . . . . . . . . . . . . . . . .018–.026 . (,45–,65 mm) Maximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..079 . . (2, mm) Distance Between Piston & Head . . . . . . . . . . . . . . . . . . . . ..031–.039 . (,80–1,0) Compression Pressure . . . . . . . . . . . . . . . . . . . .355–575 .

PSI (2445–3960 kPa) NOTE: Both cylinders must be within 35 PSI (240 kPa).

I.D. of Hole for Wrist Pin Bushing . . . . . . . . . . . . . .1.3386–1.3392 (34,–34,016) I.D. of Wrist Pin Bushing . . . . . . . . . . . . . . . . . 1.1877–1.1841 .

(30,040–30,076) I.D. of Big End . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2441–2.2448 ..

(57–57,019) Rod–to–Crankshaft Clearance . . . . . . . . . . . . . . . . . . . ..002–.0044 . (,050–,112) Rod–to–Crankshaft (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..012 . . (,3) Rod–to–Crankshaft Side Clearance . . . . . . . . . . . . . . . . . .006–.012 . (,170–,271)

154 of 216

–6–32–

600, 600D, 610, 611 Loader Service Manual

6–8.6 Camshaft, Crankshaft, Bearings Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..006–.024 .. (,15–,60) Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .039 ....

I.D. of camshaft Bushing . . . . . . . . . . . . . . . . . . 1.8901–1.8923 .

(48,01–48,064) Diameter of Crankpin, Standard . . . . . . . . . . . . . .2.046–2.0468 (51,971–51,99) Diameter of Crankpin, 1st Undersize . . . . . . . . . 2.0264–2.0272 (51,471–51,49) Diameter of Crankpin, 2nd Undersize . . . . . . . . 2.0067–2.0075 (50,971–50,99) Diameter of Crankpin, 3rd Undersize . . . . . . . . . 1.9870–1.9878 (50,471–50,49) Width of Crankpin . . . . . . . . . . . . . . . . . . . . . . . . . .1.3386–1.3401 .

(34,–34,039) Diameter of Crankshaft Main Journals, Standard . . . . . . . . . . . .2.4398–2.4406 (61,971–61,99) Diameter of Crankshaft Main Journals, 1st Undersize . . . . . . . . 2.4201–2.4209 (61,471–61,49)) Diameter of Crankshaft Main Journals, 2nd Undersize . . . . . . . . 2.4004–2.4012 (60,971–60,99)) Diameter of Crankshaft Main Journals, 3rd Undersize . . . . . . . . 2.3807–2.3815 (60,471–60,490) Crankshaft Center Journal, Standard . . . . . . . . . . 2.361–2.3618 (59,971–59,99) Crankshaft Center Journal, 1st Undersize . . . . 2.3414–2.3421 (59,471–59,490) Crankshaft Center Journal, 2nd Undersize . . . . 2.3217–2.3224 (58,971–58,99) Crankshaft Center Journal, 3rd Undersize . . . . . 2.302–2.3028 (58,471–58,49) Maximum Out–of–Round Tolerance of Journals . . . . . . . . . . . . . . . . .0027 . (,07) End Play of Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..008–.016 .. (,2–,4) Hardness of Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rc . . .53–60

6–9.1 Mainframe & Hydraulics

Part Number

Wrench, Axle Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See . . Parts Manual Chain Breaker Tool (Size No. 50) Chain Breaker Tool (Size No. 80) Tank Spreaders (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6501120–Clark ...

Hydraulic Cylinder Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . .6506050–Clark .

Boom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See . . . Parts Manual Y–90 Tester & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See . . Parts Manual 6–9.2 Deutz Engine Tools 100020 100030 101900 101910 121100 122100 122230 122800 122970 123310 124020 123830 130300 130510 131000 139000 141000 143620 150010 150800

155 of 216

Compression checking tool Compression check tool Angle of turn gauge for head bolts Angle for nozzle removal (use with 150800) Valve spring tool Valve service tools Valve service tools Valve service tools Valve service tools Valve service tools Valve service tools Valve service tools Piston ring tool Piston ring compressor Wrist pin mandrel Heater for piston Puller for end cover and gears Tool for installing camshaft bearings Tool for reconditioning cylinder face on crankcase Puller tool

–6–33–

Dealer Copy -- Not for Resale

6–9 SPECIAL TOOLS

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

610,611ServiceManual#6556276–DeutzEngineServiceSection

156 of 216

–6–34–

600, 600D, 610, 611 Loader Service Manual

Paragraph Page Number Number CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.7 ..

7–7 CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.3 ..

7–3 CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .7–1.8 .

7–8 CONNECTING ROD REMOVAL . . . . . . . . . . . . . . . . . . . . . . .7–1.2 .

7–2 CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.2 ..

7–2 CYLINDER AND PISTON INSTALLATION . . . . . . . . . . . . . . . .7–1.9 7–8 CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . 7–1.11 .

7–9 DECOMPRESSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 7–1.14 .

7–10 ENGINE DISASSEMBLY AND REPAIR . . . . . . . . . . . . . . . . . .7–1 7–1 FUEL AND OIL FILTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . 7–1.17 .

7–10 FUEL FILTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.16 ..

7–10 FUEL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .7–1.15 .

7–10 INJECTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.19 ..

7–11 LUBRICATING OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.6 ..

7–6 OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.5 ...

7–4 OIL PUMP AND GOVERNOR ASSEMBLY REMOVAL . . . . . 7–1.4 7–4 PISTON ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–1.10 ..

7–9 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–2 ..

7–12 TIMING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–1.18 ..

7–10 VALVE ROCKER ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . .7–1.13 .

7–10 VALVE ROCKER GEAR INSTALLATION . . . . . . . . . . . . . . . . .7–1.12 7–10

Dealer Copy -- Not for Resale

PETTER ENGINE SERVICE

PETTER ENGINE SERVICE

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600, 600D, 610, 611 Loader Service Manual

7 PETTER (ENGINE RECONDITIONING) 7–1 ENGINE DISASSEMBLY AND REPAIR 1. Remove crankcase oil.

2. Remove exhaust manifold assembly ( Fig. 7–1).

3. Disconnect pump to injection pipes, disconnect air cleaner hose, remove manifold and cylinder air housing.

C–02120

Fig. 7–1 Remove Exhaust Manifold

Fig. 7–2 Remove Rocker Cover

5. Remove fuel injectors (Fig. 7–3).

6. Remove rocker assembly and valve caps. Remove push rods (Fig. 7–4).

B–02371

Fig. 7–3 Remove Fuel Injectors

C–02122

Fig. 7–4 Remove Rocker Assembly

7. Remove cylinder head nuts and remove cylinder heads.

Remove push rod covers and seals (Fig. 7–5).

8. Mark crankcase and cylinder for assembly position. Turn crankshaft until piston is TDC and pull cylinder barrel from piston (Fig. 7–6).

C–02119

Fig. 7–5 Remove Cylinder Head

Dealer Copy -- Not for Resale

4. Remove rocker cover nut, pull decompressor lever away from rocker cover, against spring pressure, lift cover of f (Fig. 7–2).

C–02118

Fig. 7–6 Remove Cylinder Barrel

NOTE: Check number and size of shims between cylinder and crankcase, before removal (Fig. 7–7).

9. Remove piston by removing piston pin snap rings (Fig. 7–8).

C–02121

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B–01878

Fig. 7–7 Cylinder Shims

Fig. 7–8 Remove Piston Pin Snap Rings

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600, 600D, 610, 611 Loader Service Manual

10. Remove four retainer bolts and remove crankshaft extension.

Remove two flywheel retainer bolts and install two longer bolts of same diameter. Remove the remainder retainer bolts and use puller to remove flywheel (Fig. 7–9).

11. Remove flywheel air guide inside bell housing and the fan guard (Fig. 7–10).

B–02372

Fig. 7–9 Removal of Flywheel

7–1.1 Removal Of Connecting Rod

C–02097

Fig. 7–10 Remove Air Guide & Fan Guard

2. Loosen large end bolts and remove connecting rods.

Check position in which connecting rod caps are installed, number sides together for identification (Fig. 7–12).

Dealer Copy -- Not for Resale

1. Put engine on its flywheel housing. Remove oil pan fastening nuts, oil pan and air guide plate (Fig. 7–11).

B–02310

Fig. 7–11 Remove Air Guide Plate

B–02386

Fig. 7–12 Remove Connecting Rod Caps

7–1.2 Removal Of Crankshaft 1. Remove gear cover nuts, cover has dowel fit to crankcase.

Remove dowels to prevent damage (Fig. 7–13).

C–02147

Fig. 7–13 Remove Timing Gear Cover 160 of 216

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2. Remove bolts holding crankshaft gear wheel. The gear wheel has dowel fit to crankshaft. Remove dowels.

Do not damage teeth on gear wheel (Fig. 7–14).

3. Remove oil strainer assembly .

Remove bolts, locking plates and bottom half of bearing.

Remove top half of bearing housing, turn it 180° by turning crankshaft (Fig. 7–15).

C–02102

Fig. 7–14 Remove Crankshaft Bear

4. Remove nuts, washers and oil seal housing. Remove thrust collar retainer bolt and plate.

Remove thrust collar.

B–02370

Fig. 7–15 Remove Main Bearing

Dealer Copy -- Not for Resale

5. Remove main bearing housing nuts and washers. Remove housing and pull crankshaft (Fig. 7–16).

7–1.3 Removal Of Camshaft 1. Remove fuel injection pumps. check number of shims and thickness between fuel pump flanges and crankcase (Fig. 7–17). these shims control fuel pump timing. Remove fuel filter assembly (Fig. 7–18).

2. Put rubber band around stems of valve tappets to prevent damage to toe pieces when pulling camshaft.

Turn camshaft so fuel pump tappets are clear of shaft. Remove camshaft bearing housing nuts through holes in gear wheel.

Then camshaft and bearing housing can be pulled (Fig. 7–19).

C–02094

Fig. 7–16 Remove Crankshaft

B–02342

Fig. 7–17 Check Number of Shims

A

A–02322

Fig. 7–18 Fuel Filter Assembly 161 of 216

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Fig. 7–19 Removing Camshaft 600, 600D, 610, 611 Loader Service Manual

3. Pull fuel pump tappets 7–20).

(Fig.

4. To remove camshaft gearwheel, hold camshaft in a vice using protected vice fasteners so that there will be no damage to the shaft.

Remove gearwheel retainer plate, bolt, plate and retainer plate oil seal. Pull gear wheel (Fig. 7–21). Remove bearing housing assembly.

C–02105

7–1.4 Removal Of Oil Pump And Governor Assembly

A–02146

Fig. 7–20 Pull Fuel Pump Tappets

B–02311

Fig. 7–22 Remove Governor Level

2. Remove oil pump retainer bolts, pump and governor assembly.

Remove snap ring retainer for governor thrust cone, thrustwasher, cone and governor balls (Fig. 7–24).

7–1.5 Oil Filter 1. Remove bolt at center of filter cover and pull cover and element. Remove relief valve, plunger and spring (Fig. 7–25).

C–02103

Fig. 7–23 Governor Rack Removal

C–02092

NOTE: Clean all parts and inspect for wear. All worn parts must be installed new. The bearings are of precision thin wall steel backed sleeve type, lined with bearing metal.

The bearings can be pressed or driven out.

Fig. 7–24 Removing Oil Pump

Check that crankcase oil holes are clean, make sure that part numbers on outer face of bearings are not rough. Burrs must be removed before bearing is put into its housing.

2. Remove main bearing, gear end, using correct tool (Fig. 7–26).

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B–02308

Fig. 7–25 Remove Oil Filter –7–4–

C–02106

Fig. 7–26 Remove Main Bearing (Gear End) 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

1. Remove bolts fastening speed control plate. Push out speed control lever pin and pull lever.

Remove lever shaft boss, first pushing out stop/run lever pin, then remove lever, shaft bolt and oil seal.

Remove adjustment bolt, spring and pillar assembly from governor rack.

Do not change adjustment bolt (Fig. 7–22).

Remove governor lever, speed spring and shaft assembly.

Remove stop/run lever shaft assembly. Pull governor rack without doing damage to shaft (Fig. 7–23).

Fig. 7–21 Remove Camshaft Bearing Housing

3. When installing a new main bearing, gear end, use correct tool. New bearings are of special size to give correct fit when in position.

NOTE: Undersize bearings are available in size .020 inch or .040 inch (5,08, 10,16 mm).

B–01252

4. Inspect camshaft bearings, gear and flywheel end. These are pressure lubricated bearing bushings and are installed using correct tool (Fig. 7–27).

Fig. 7–27 Camshaft, Gear, and Flywheel End Bearing

6. Install a new main bearing, flywheel end (Fig. 7–29).

A–02327

Fig. 7–28 Remove Flywheel End Main Bearing 7. Install new crankshaft thrustwashers, check that groove sides are away from bearing housing. The washers are dowel positioned and must be installed with new dowel pins (Fig. 7–30).

Dealer Copy -- Not for Resale

5. Remove flywheel end main bearing after removing thrustwashers. Use correct tool for removal (Fig. 7–28).

A–02328

Fig. 7–29 Install New Bearing (Flywheel End)

8. Inspect crankshaft bearing journals and crankpins.

B–01251

Fig. 7–30 Install Crankshaft Thrust Washers 163 of 216

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9. Before installing crankshaft, check that journal bearing surfaces and oil holes are clean (Fig. 7–31).

10. Add lubricant to gear end main bearing and shaft journals then install crankshaft. Install top half of intermediate main bearing housing after first putting lubricant on bearing and center journal of shaft (Fig. 7–32).

A–02144

Fig. 7–31 Oil Outlet on Crankshaft

B–02340

Fig. 7–32 Install Crankshaft

11. Lubricate baring and journal, then install flywheel end main bearing housing using a new gasket (Fig. 7–33).

13. Install thrust collar and fasten this with collar key . Inspect oil seal and housing before installation (Fig. 7–35).

C–02099

Fig. 7–33 Install Main Bearing Housing

C–02101

Fig. 7–34 Install Shaft Thrust Collar

14. When housing and seal is new, check that seal is installed to correct rotation, which is marked by an arrow stamped on seal (Fig. 7–35).

15. Check that oil seal and housing are in position (Fig. 7–36).

16. Install fan guard and air guidein correct positions (Fig. 7–37).

A–02318

Fig. 7–35 Inspect Oil Seal & Housing

C–02100

Fig. 7–36 Oil Seal & Housing Position

7–1.6 Lubricating Oil Pump 1. Check condition of rotor and stator. When worn, install new pump. Put engine oil into pump through opening before installing on engine. Install new gasket, install pump and tighten bolts to 10 ft.–lbs. (1.39 Kgfm) (Fig. 7–38).

C–02098

Fig. 7–37 Fan & Air Guide 164 of 216

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B–01256

Fig. 7–38 Oil Pump 600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

12. Install new O–ring then install shaft thrust collar (Fig. 7–34).

2. Install valve tappets and hold in position using rubber bands.

Install fuel pump tappets and socket headed plugs. 3/4 inch BSP (taper) (Fig. 7–39).

C–02107

Fig. 7–39 Install Fuel Pump Tappets Camshaft

1. Inspect fuel pump tappet bushing for wear , install new when needed.

Check thrustwashers (1) for wear and install new if worn. When washers are removed, install new dowel pins (2). Put lubricant on bearing bushing and shaft journal surface.

Install bearing housing assembly (3) onto shaft. Check that keyway is in line with key (4). Install new oil seal ring (5) behind gear holding plate (6), then install plate and fastening bolt.

3

2

2 6

4 1

5

B–01252

Fig. 7–40 Camshaft

2. Lubricate gear end bearing bushing, and camshaft bearing surfaces, put in camshaft assembly. Install and tighten camshaft bearing housing nuts and washers. T ighten gear fastening bolt to 25 ft.–lbs.

(3,46 Kgfm) (Fig. 7–41).

3. Lubricate and install bottomhalf of intermediate main bearing housing assembly. Tighten fastening bolts in correct sequence. All bolts to be tightened finger tight, then tighten evenly working diagonally across bearing cap until bolts are tightened to 25 ft.–lbs. (3,46 Kgfm).

4. Install crankshaft gear checking that teeth marked with dots are in position. T ighten bolts to 35 ft.–lbs. (4,84 Kgfm) (Fig. 7–42).

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7–1.7 Installation Of (Fig. 7–40)

B–02369

Fig. 7–41 Torquing Gear Fastening Bolt

CAMSHAFT–CRANKSHAFT TIMING Fig. 7–42 Timing Crankshaft Gear –7–7–

CAMSHAFT BALANCE TIMING 600, 600D, 610, 611 Loader Service Manual

5. Install governor assembly , using new gasket and oil seal rings (Fig. 7–43).

6. Check governor thrust clearance. Move stop/run lever into Run position, then check clearance between thrust bearing and fork on governor lever. Correct clearance is between 0.005–0.025 inch (0,27–0,635 mm), with fuel pump rack in full fuel position.

Install gear cover using new cover gasket.

B–01253

Fig. 7–43 Governor Assembly

7. Install flywheel (Fig. 7–44).

8. Tighten bolts to 35 ft.–lbs. (4,84 Kgfm).

9. Check crankshaft end play .

This should be 0.0075–0.0185 inch (0,191–1,470 mm) (Fig. 7–45).

1. When needed, install a new small end bushing in pistons.

Check that oil feed hole in bushing is in alignment with connecting rod hole. Before installing connecting rods, assemble cap and rod withnew bearings, checking that bearing halves are in correct position.

When assembling connecting rods to crankshaft, check that matching numbers are together on correct side and that connecting rod cap is towards dipstick side of engine (Fig. 7–46). Tighten bolts to 40 ft.–lbs. 5,53 Kgfm) torque.

C–02093

Fig. 7–44 Install Flywheel

2. Install oil pump using a new gasket and air guide, with opening toward gear end of engine (Fig. 7–47).

7–1.9 Installation Of Cylinders And Pistons 1. Check the cylinders for wear.

Always hone the bores using medium grade emery cloth.

Clean cylinders after they are honed. To check piston rings for wear, put piston in cylinder towards end of bore and about 1/2 inch (12,7 mm) from bottom crown to check that it is level in bore. The gap can now be checked with a feeler gauge and maximum permissable wear can not be more than 0.040 inches (1,02 mm). New ring gap is 0.010–0.015 inches (0,25–0,38 mm)

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B–02367

Fig. 7–45 Crankshaft End Play

Fig. 7–46 Install Connecting Rod Caps

A–02145

Fig. 7–47 Air Guide –7–8–

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

7–1.8 Connecting Rod Assembly

Piston Assembly (Fig.

1. Assemble rings on piston in correct order, with correct face up. The scraper rings must be put in fourth (bottom) groove, the two stepped compression rings in third groove and second groove, wtih step facing up, chrome compression ring in the top groove with widest internal chamber facing up. Check that ring gaps are not in line but spaced around piston. Install piston on connecting rods and install piston pin. Check that snap ring is correctly installed in its groove. Rings must not have play or be solid in groove. T o check; with piston held in a horizontal position, rings must not fall down, unless piston is moved. Before installing the cylinders, check that length of studs from face of crankcase to top of studs are correct (i.e.

8.370–8.410 inches). The studs can appear loose in their helicoil fittings, but this is correct (Fig. 7–48).

B–02309

Fig. 7–49 Install cylinders

Fig. 7–48 Piston Assembly

Dealer Copy -- Not for Resale

7–1.10 7–48)

2. Install shims between cylinder and crankcase. Thickness of shims control head clearance between piston and cylinder head at T .D.C. Lubricate cylinder bores, piston, compressing rings by hand (Fig. 7–49).

3. The head clearance must now be checked. Put three pieces of lead wire approximately 1/2 inch long, on top of piston crown. Install cylinder head and tighten bolts. T urn crankshaft over top dead center.

4. Remove cylinder head and measure thickness of lead wire with a micrometer . Correct thickness of wire when flat is 0.032–0.037 inch (0,81–0,94 mm). When clearance is not correct, remove or addrequired shims to give correct head clearance (Fig. 7–50).

A–02319

Fig. 7–50 Lead Wire thickness

5. Install push rod covers using new gaskets and new seals.

7–1.11 Installation Of Cylinder Heads 1. Tighten cylinder head nuts correctly and in right sequence.

Tighten each nut until finger tight. Then tighten each nut 1/4 of a turn at a time, diagonally across cylinder head. T ighten to 34 ft.–lbs. (4,70 Kgfm).

Check with a straight edge before tightening cylinder head nuts (Fig. 7–51).

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B–02383

Fig. 7–51 Install Cylinder Head –7–9–

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7–1.12 Installation Of Valve Rocker Gear 1. Install valve push rods and rocker assemblies. Rocker nut must be tightened to 15 ft.–lbs. (2,07 Kgfm).

7–1.13 Adjustment Of Valve Rockers 1. Loosen decompressor adjustment lock nuts and screw out adjustors clear of decompressor cam. Make adjustment of valve rocker clearance. Set engine with both valves closed and piston at T .D.C. firing stoke. Loosen rocker adjustment screw lock nut, and turn adjustment screw to give a clearance of .004 inches on both valves. When this figureis correct, tighten rocker lock nut and check gap. Check valve clearance when engine is cold (Fig. 7–52).

7–1.14 Adjustment Of Decompressor 1. Turn decompressor ratchet in a clockwise direction until lock engages with ratchet teeth. Turn in decompressor adjustment until it touches decompressor cam and then turn in adjustment a third of a turn only . Set lock just toughing block and make sure that lock is lined withratchet wheel teeth.

Tighten locknut (Fig. 7–53).

B–02375

Fig. 7–52 Valve Adjustment

7–1.15 Fuel Pump Installation

Dealer Copy -- Not for Resale

1. Check that fuel pump cam is at bottom of its stroke by turning crankshaft until exhaust or inlet valve is open. Install fuel pump shims. Move stop/run lever until groove in governor rack is in center of fuel pump aperture in crankcase (Fig. 7–54).

2. Fuel pump rack can now be moved so that rack ball is in center position, then install pump, checking that ball has engaged with governor rack. Check that mark on pump flange lines up with center hole in crankcase. T ighten nuts (Fig. 7–55).

7–1.16 Fuel Filter Assembly 1. Install new filter element. Do not clean oil filter element.

7–1.17 Fuel And Oil Filter Assembly 1. Install new filter element. Check relief valve and valve seat. When worn or damaged the oil filter head assembly must be installed new.

2. Install fuel and lube oil filter assemblies. Connect fuel pipes, pump to filter. Install fuel tank and fuel pipe tank to filter. Tighten bolts of each filter head to 10 ft.–lbs.

(1,39 Kgfm). The filter head gaskets must be new.

B–02341

Fig. 7–53 Adjusting Decompressors

3. Wash out fuel tank with clean fuel oil. Install tank and pipe from tank to fuel filter. Check that fuel line is air free to fuel pumps.

7–1.18 Timing The Engine 1. To time the engine, perform the timing on one cylinder at a time. No. 1 cylinder is at gear end. Timing of fuel pump must be done only when engine is cold. Move the stop/run lever to middle position.

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Fig. 7–54 Install Fuel Pump –7–10–

Fig. 7–55 Injector Pump Alignment 600, 600D, 610, 611 Loader Service Manual

2. Remove discharge union from pump (Fig. 7–56).

3. Lift out delivery valve and spring peg and put them in a container of clean fuel (Fig. 7–57).

NOTE: Do not move delivery valve seat or joint washer .

4. Install union body, leaving out delivery valve and spring peg. Install short spill pipe. Turn flywheel until it is a quarter of a turn before.D.C. T on compression stroke. Pour fuel into fuel tank. A stream of fuel will now flow from fuel pump.

Turn flywheel slowly by hand, in normal running direction until flow from the fuel pump stops.

5. Check for correct flywheel position at time which this happens. Position is known as spill point. When flywheel is in correct position where flow stops, the approximate timing marks before the T.D.C. mark on the flywheel, must be in line with hole in bell–housing.

6. When timing mark indicates position before bell–housing hole, add shims between fuel pump and crankcase until correct. When timing indicates position after bell–housing hole, remove shims to obtain correct timing (Fig. 7–58).

C–02104

Fig. 7–56 Remove Discharge Union

Dealer Copy -- Not for Resale

7. Assemble fuel injection equipment, including fuel delivery valve and spring.

Make sure that union body and sealing ring is fitted correctly. Tighten union to 45 ft.–lbs. (6,2 m/Kgf).

7–1.19 Injector Installation 1. Set injectors to a pressure of 3250 lbs. sq. in (228,5 Kfg/cm Sq.). To make adjustment of release pressure, loosen spring adjustment screw lock nut.

Turn adjustment screw clockwise to increase pressure, and counterclockwise to decrease. Tighten lock nut (Fig. 7–59).

2. Install injectors. Check that sealing washers are in good condition. The fastening nuts must be tightened to 15 ft.–lbs. (2,07 Kgfm).

3. Install rocker box covers. Install cylinder housing, and fastening nuts and bolts.

tighten fuel tank

A–02330

Fig. 7–57 Disassembling Pump

C–02096

Fig. 7–58 Fuel Pump Shims 169 of 216

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C–02095

Fig. 7–59 Injector Adjustment 600, 600D, 610, 611 Loader Service Manual

7–2 TECHNICAL DATA (Fits, Clearances & Torques)

610,611ServiceManual#6556276–PetterEngineServiceSection

Camshaft End Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003–0.015 ...

Crankshaft End Float (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0075–0.0185 ..

Crankshaft End Float (not to exceed) . . . . . . . . . . . . . . . . . . . . . . . . . . . ..0.025 ..

Crankshaft Out–Of–Round (not to exceed) . . . . . . . . . . . . . . . . . . . . . . . . .0.003 .

Cylinder Bore Wear (not to exceed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 ..

Piston Ring Gap (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.010–0.015 ..

Piston Ring Gap (not to exceed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.040 ..

Exhaust Valve Lift by Decompressor (maximum) . . . . . . . . . . . . . . . . . . . . 0.025 .

Bumping Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.032–0.037 ...

Valve Rocker Clearance (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.004 ..

Main Bearing Clearance (new) . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0012–0.0028 ..

Connecting Rod Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . .0.0015–0.0030 .

Connecting Rod Small Bushing Diameter (installed) . . . . . . . . . . 1.1253–1.1258 Valve Depth From cylinder Head Face (new) . . . . . . . . . . . . . . . . . .0.028–0.053 Valve Guide Bore Diameter (installed) . . . . . . . . . . . . . . . . . . . . .0.3125–0.3134 .

Cylinder Reboring Diameters: Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5000–3.5010 ...

Oversize: 0.020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5200–3.5210 ....

0.040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5400–3.5410 ....

Standard Undersize: 0.010 0.020 0.030 0.040

Main Journal 2.9995/2.9990

Intermediate Journal 2.74585/2.7480

Crankpin 2.1250/2.1245

2.9895/2.9890 2.9795/2.9790 2.9695/2.9690 2.9595/2.9590

2.7385/7.7380 2.7285/2.7280 2.7185/2.7180 2.7085/2.7080

2.1150/2.1145 2.1050/2.1045 2.0950/2.0945 2.0850/2.0845

Dealer Copy -- Not for Resale

Crankshaft Regrinding Diameters:

Torque Wrench Settings: Connecting Rod Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 . ft.–lbs.

Cylinder Head Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 . . ft.–lbs.

Injector Mounting Stud Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . ft.–lbs.

Lubricating Oil Filter Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . ft.–lbs.

Fuel Filter Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 . . ft.–lbs.

Flywheel Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . .ft.–lbs.

Crankshaft Gear Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . ft.–lbs.

Camshaft Gear Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 . . ft.–lbs.

Flywheel End Extension Shaft Screw . . . . . . . . . . . . . . . . . . . . . . . . 25 . ft.–lbs.

Camshaft Extension Shaft Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 . ft.–lbs.

Rocker Support Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 . . ft.–lbs.

Center Main Bearing Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . ft.–lbs.

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SPECIFICATIONS Paragraph Number

Page Number

ENGINE SPECIFICATIONS (WISCONSIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8A–1

WISCONSIN

DEUTZ

ENGINE SPECIFICATIONS (DEUTZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8B–1

ENGINE SPECIFICATIONS (PETTERS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8C–1

MOTOR SPECIFICATIONS (ELECTRIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8D–1

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8E–1

PETTER

ELECTRIC

Dealer Copy -- Not for Resale

TECHNICAL DATA

SPECIFICATIONS

171 of 216 Revised Dec. 78

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600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale 172 of 216

–8A––2

600, 600D, 610, 611 Loader Service Manual

ENGINE SPECIFICATIONS (WISCONSIN)

WISCONSIN

Dealer Copy -- Not for Resale

Paragraph Page Number Number ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–1 ..

8A–1 LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8A–3

173 of Dec. 216 78 Added

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600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale 174 of 216

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600, 600D, 610, 611 Loader Service Manual

8A TECHNICAL DATA 8A–1 ENGINE SPECIFICATIONS (Wisconsin) All specifications are given in inches with metric parentheses.

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107.7 . . cu. in. (1,76 liters) Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 . . . . (82,55 liters) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 . . . . (82,55 liters) Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–3–4–2 ...

Oil Capacity W/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. gal. . (3,79 liters) Maximum RPM (Full Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2800 . . RPM Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 . . . . RPM Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . .4–5 . PSI (27,6–34,5 kPa) (Normal)– 15 PSI (103,4 kPa) (Maximum) Fuel Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .2–3 . PSI (13,8–20,7 kPa) 8A–1.1 Fuel Specifications Always use clean fuel. Do not let the fuel tank become empty.

Type of Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regular .. gasoline 85–90 octane 8A–1.2 Engine Oil

Check oil level after every 8 hours of operation (Check oil every 4 hours on new engine during the first 50 hours of operation).

Oil level must be maintained between the add and full marks on the dipstick.

Specifications: Use a good quality detergent motor oil that meets the correct API service classification.

Use oil of proper SAE viscosity for expected temperature conditions at the time of starting, not for the highest temperature expected during the working day.

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE) C°–34 –29

–23 –18

–13

–7

–1

+4

+10 +15

+21

+27 +32 +38

+43

+49

+54 +60

+70

+80 +90 +100 +110 +120 +130 +140

Dealer Copy -- Not for Resale

System:

SAE 10W–30

SAE 15W–40 SAE 5W–30 SAE 30W

SAE 20W–20

SAE 10W

F°–30 –20

–10

0

+10

+20 +30

+40 +50 +60

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (GASOLINE: USE API CLASSIFICATION SE) (DIESEL: USE API CLASSIFICATION CD)

Use summer recommendations in winter if machine is kept in warm building.

175 of 216 Revised March 80

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600, 600D, 610, 611 Loader Service Manual

8A–1.3 Valve Mechanism Valve Stem Clearance in Guide . . . . . . . . . . . . . . . . . . . . . . .003 .

(0,076–0,127) Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .007 . . . (0,178) Valve Tappet Clearance: Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..008 . . . (0,203) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..016 . . . (0,406) 8A–1.4 Crankshaft Crank Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . .1.875–1.876 .

(47,625–47,650) Crank Pin Length . . . . . . . . . . . . . . . . . . . . . . . . . .1.130–1.135 .

(28,702–28,829) Crankshaft End Play (Cold) . . . . . . . . . . . . . . . . . . . . . .002–.004 .

(0,051–0,102) 8A–1.5 Idler Gear Idler Gear to Shaft Collar Clearance . . . . . . . . . . .0015–.0035 (0,0381–0,0889) 8A–1.6 Connecting Rod Connecting Rod to Crank Pin Clearance (Diameter) .0012–.0033 (0,030–0,086) Connecting Rod to Crank Pin Clearance (Side Clearance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..009–.018 .

(0,229–0,457) Connecting Rod Busing to Piston Pin Clearance . . .0005–.0011 (0,013–0,028) 8A–1.7 Piston, Piston Pin, Piston Rings

Dealer Copy -- Not for Resale

Piston to Cylinder at Piston Skirt (Wide Skirt) . . . . . .0035–.0040 (0,089–0,102) Piston Pin to Piston clearance . . . . . . . . . . . . . . . . . ..0000–.0008 (0,000–0,020) Piston Ring Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010–.020 ..

(0,254–0,508) Piston Ring Side Clearance in Grooves: Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..002–.0035 ..

(0,051–0,089) 2nd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..001–.0025 ..

(0,025–0,064) 3rd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..001–.0025 ..

(0,025–0,064) Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..0025–.004 ..

(0,064–0,101) 8A–1.8 Ignition System Breaker Point Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..018–.022 .

(0,458–0,559) Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .030 . . . (0,762) 8A–1.9 Distributor Advance Characteristics VH4D The distributor has an automatic advance. The automatic advance is 11–1/2° in the distributor, equal to 23° on the crankshaft. The distributor is fully advanced at 1800 RPM engine speed or above.

VF4D The distributor has an automatic advance. The automatic advance is 13–1/2° in the distributor, equal to 27° on the crankshaft. The distributor is fully advanced at 1800 RPM engine speed or above.

8A–1.10 Starter the starter is the gear drive type and is 12 volt, negative ground.

8A–1.11 Engine Torque Specifications Item Ft.–Lbs. Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–24 ..

Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25–30 ..

Manifold Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18–23 ..

Timing Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–18 ..

Oil Pan Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–9 ..

Connecting Rod Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–28 ..

Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40–50 ..

Main Bearing Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . .25–30 .

Flywheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40–60 ..

176 of 216 Revised February 80

–8A–2

Nm 30–33 34–41 24–31 19–24 8–12 30–38 54–68 34–41 54–81

600, 600D, 610, 611 Loader Service Manual

600 LOADER (WISCONSIN GAS)

55.1 (1399.51)

138 (3505) 120 (3048)

38°

31 (787)

101 (2565) 86 (2184)

45°

60 (1524)

41 (1041) 27°

79 (2007)

8 (203)

8 (203)

35 (889)

15 (381)

25°

41.5 (1054 ) 48 (1219)

34 (864)

53 (1359)

107 (2718)

46 (1168) PI–01458

Dimensions are given for loader equipped with dirt bucket and may vary with other bucket types. All dimensions are shown in inches. Metric dimensions are given in millimeters enclosed by parentheses.

OPERATIONAL & PERFORMANCE Operating Weight . (Gasoline) 3625 (1645 kg) (LP Gas) 3695 (1677 kg) Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . 1000 . lbs. (453,6 kg) Lift Capacity to Maximum Height . . . . . . . . . . . Gas 1700 lbs. (771,8 kg) LP Gas 1700 lbs. (771,8 kg) Tipping Load . . . . . . . . . . . . . . . . . . . . . . . . . . .Gas . 1880 lbs. (853,3 kg) LP Gas 1990 lbs. (903,4 kg) Hydraulic Function Time: Raise to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.0 . sec.

Lower from Maximum Height. . . . . . . . . . . . . . . . . . . . . . . . . . .2.5 . sec.

Dumping Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 . . sec.

Rollback Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 . . sec.

Travel Speed . . . . . . . . . Infinitely variable to 5.7 MPH forward & reverse Controls: Vehicle . . . . . . . . . . . . . . . . . . . . Forward, . reverse & steering functions controlled by two hand levers Travel Speed . . . . . . . Hand lever controlled, adjusted variable sheave.

Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift, . . tilt & auxiliary functions controlled by separate foot pedals.

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . Handle .. lever throttle, manual choke & key–type ignition–starter switch.

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wisconsin ...

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VF4D ...

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gasoline .. or LP Gas Governed Flywheel Horsepower . . . . . . . . . . 25 (18,6 kw) @ 2400 RPM Maximum Torque . . . . . . . . . . . . . .57.5 ft.–lbs. (77,9 Nm) @ 1800 RPM Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25x3.25 .

(82,5x82,5) Displacement . . . . . . . . . . . . . . . . . . . . . . . . . 107.7 .. cubic inches (1,8L) Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . volt distributor Cooling Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air ...

Lubrication Filtration . . . . . . . Replacement element, full flow w/by–pass Crankcase Ventilation . . . . . . . . . Internal breathing w/sealed carburetor Air Cleaner . . . . . . Replaceable dry cartridge type w/condition indicator 177 of 216 Revised February 80

65 (1651)

Dealer Copy -- Not for Resale

17.75 (450)

81.7 (2075)

108 (2743)

Where applicable, specifications conform t o ICED & SAE standards and are subject to change without notice.

LOADER HYDRAULICS Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine .. driven, gear type Minimum Pump Capacity . . . . . . . . . .9.5 GPM (35,95L/M) @ 2400 RPM System Relief Setting . . . . . . . . . . . . . . . . . . . . . . 1700 PSI (11721 kPa) .

Filtration . . . . . Full flow on suction port of pump with by–pass, condition indication & 33 micron replaceable paper element Cylinders . . . . . . . . . . . . . . . . Doubleacting . w/ Teflon seals & wear rings Function Lift Tilt 2’’ (50,8 mm) 2’’ (50,8 mm) Bore Diameter Rod Diameter 1.25’’ (31.75 mm) 1’’ (25,4 mm) Stroke 25’’ (635 mm) 16’’ (406,4 mm) Valves . . . . . . . . . . . . . . . . . . . Open–center . type with float detent on lift ELECTRICAL Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . 22 . . amp. enclosed belt driver.

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 . . amp.–hr. rating 12 volt Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . volt gear drive DRIVE SYSTEM Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Variable . sheave type Clutches . . . . . . . . . . . . . .4 (2 each side) single disc pressure lubricated Primary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.00:1 ..

Secondary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.00:1 ..

Final Drive . . . . #60H roller chain running in sealed oil bath (2.92:1 ratio) Total Engine to Wheel Reduction . . . . . . . . . Variable from 37:1 to 100:1 CAPACITIES Fuel . . . . . . . . . (Gasoline) 10 gal. (37,85 L) (LP Gas) 33 lbs. (14,98 kg) Engine Lubricant Including Filter . . . . . . . . . . . . . . . . . . . . . . 4. qt. (3,8 L) Hydraulic Reservoir & Final Drive Case . . . . . . . . . . . . . . 17 gal. (75,7 L) Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 . gal. (75,7 L) TIRES Standard . . . . . . . . . . .Melroe special bar 7:00x15–6 ply steel cap nylon Pressure . . . . . . . . . . . . . . . . . . . . . .45–50 .

PSI (310,275–344,750 kPa) COUNTERWEIGHT Standard Cast Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 . lbs. (45,4 kg) MACHINE WEIGHT (Less Bucket) Shipping (Gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . 3170 .. lbs. (1439 kg) Shipping (LP Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . 3280 .. lbs. (1489 kg)

–8A–3–

600, 600D, 610, 611 Loader Service Manual

610 LOADER (WISCONSIN GAS) 610,611ServiceManual#6556276–Specifications(Wisconsin)SectionPart1of5

55.1 (1399.51)

138 (3505) 120 (3048)

38°

31 (787)

101 (2565) 86 (2184)

45°

60 (1524)

41 (1041) 27°

79 (2007)

8 (203)

8 (203)

35 (889)

15 (381)

25°

41.5 (1054 ) 48 (1219)

34 (864)

53 (1359)

107 (2718)

46 (1168) PI–01458

Dimensions are given for loader equipped with dirt bucket and may vary with other bucket types. All dimensions are shown in inches. Metric dimensions are given in millimeters enclosed by parentheses.

OPERATIONAL & PERFORMANCE

Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 . . lbs. (1800 kg) Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . 1000 . lbs. (453,6 kg) Lift Capacity to Maximum Height . . . . . . . . . . . . . . . . .2190 lbs (990 kg) Tipping Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 .. lbs. (771,1 kg) Hydraulic Function Time: Raise to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6 . sec.

Lower from Maximum Height. . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 . sec.

Dumping Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 . . sec.

Rollback Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 . . sec.

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . .Infinitely . variable to 6.6 MPH (10,6 kg/hr)forward & reverse Controls: Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forward, . reverse & steering functions controlled by two hand levers Travel Speed . . . . . . . . . . . . . . . . . .Hand lever controlled, hydraulically adjusted variable sheave.

Loader Lift, tilt & auxiliary functions controlled by separate foot pedals.

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . Handle .. lever throttle, manual choke & key–type ignition–starter switch.

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wisconsin ...

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VF4D ...

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gasoline .. or LP Gas Governed Flywheel Horsepower . . . . . . . . . . . .30 (22 kw) @ 2800 RPM Maximum Torque . . . . . . . . . . . . . . . 66.2 . ft.–lbs. (90 Nm) @ 1800 RPM Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . 3.25x3.25 . in. (82,5x82,5 mm) Displacement . . . . . . . . . . . . . . . . . . . . . . . . . 107.7 .. cubic inches (1,8L) Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 . . volt breaker Cooling Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air ...

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil . . Spray Lubrication Filtration . . . . . . . Replacement element, full flow w/by–pass Crankcase Ventilation . . . . . . . . . Internal breathing w/sealed carburetor Air Cleaner . . . . . . Replaceable dry cartridge type w/condition indicator 178 of 216 80 Revised February

65 (1651)

Where applicable, specifications conform t o IDEC & SAE standards and are subject to change without notice.

LOADER HYDRAULICS Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine .. driven, gear type Minimum Pump Capacity . . . . . . . . . . .11 GPM (41,6 L/M) @ 2800 RPM System Relief Setting . . . . . . . . . . . . . . . . . . . . . . 1700 PSI (11721 kPa) .

Filtration . . . . . . . . . . . . Full flow on suction side with by–pass, condition indication & 33 micron element Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Doubleacting ..

Function Lift Tilt Bore Diameter 2’’ (50,8 mm) 2’’ (50,8 mm) Rod Diameter 1.25’’ (31.75 mm) 1’’ (25,4 mm) Stroke 25.90’’ (637,86 mm) 16.50’’ (419,10 mm) Valves . . . . . . . . . . . . . . . . . . . Open–center . type with float detent on lift ELECTRICAL Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosed . belt driven 22 amp.

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 . volt 70 amp.–hr. rating Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . volt gear drive DRIVE SYSTEM Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Variable . sheave type Clutches . . . . . . . . . . . . . .4 (2 each side) single disc pressure lubricated Primary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.00:1 .. ratio Secondary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.00:1 .. ratio Final Drive . . . . . . . . . . . . . . .#60H roller chain running in sealed oil bath Total Engine to Wheel Reduction . . . . . Variable from 37:1 to 100:1 ratio CAPACITIES Fuel . . . . . . . . . . . . . (Gasoline) 11 gal (41,6 L) (LP Gas) 33 lbs. (15 kg) Engine Lubricant Including Filter . . . . . . . . . . . . . . . . . . . . . . 4. qt. (3,8 L) Hydraulic Reservoir & Final Drive Case . . . . . . . . . . . . . . 17 gal. (64,4 L) Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 . gal. (75,7 L) TIRES Standard . . . . . . . . . . . . . . . . . . . . . . . . . .7:00x15–6 . ply steel cap nylon Pressure . . . . . . . . . . . . . . . . . . . . . .45–50 .

PSI (310,275–344,750 kPa) COUNTERWEIGHT Standard Cast Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 . lbs. (45,4 kg) Ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 . . . lbs. (140 kg) MACHINE WEIGHT (Less Attachments) Shipping . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline: .

3575 lbs. (1621,6 kg) LP Gas: 3645 lbs. (1653,4 kg)

–8A–4

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

17.75 (450)

81.7 (2075)

108 (2743)

ENGINE SPECIFICATIONS (DEUTZ) Paragraph Page Number Number ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–1 ..

8B–1 LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8B–4

Dealer Copy -- Not for Resale

DEUTZ

179 of Dec. 216 78 Added

–8B––1–

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale 180 of 216

–8B–0

600, 600D, 610, 611 Loader Service Manual

8B–1 ENGINE SPECIFICATIONS (Deutz F2L 411) All specifications are given in inches with metric parentheses.

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85.2 . . cu. in. (1,39 liters) Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.61 . . . .(91,95 L) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 . . . . (104,90 L) Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–1 ....

Oil Capacity W/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .gal. 3,79 liters) 8B–1.2 Fuel System Pressure of Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . 4–5 .

PSI (27,5–34,5 kPa) Make of Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . Bosch .

PFR2K70A414/2 Make of Fuel Injection Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . DLLA ..

152S533 Release Pressure of Injection Nozzle New–2560–2673 PSI (17649–18428 kPa) Used–2488–2602 PSI (17152–17938 kPa) Injection timing (Start of Injection) . . . . . . . . . . . . . . . . . . . . . . . . . .25° . B.T.D.C. Distance from Injection Pump Mounting Flange to Camshaft Base Circle Including gasket and shims . . . . . . . . . . . . . . . . .3.248–3.256 .

(82,5–82,7 mm) 8B–1.2 Lubrication System

Check oil level after every 8 hours of operation. (Check oil every 4 hours on new engine during the first 50 hours of operation).

Oil leverl must be maintained between the add and full mark on the dipstick. Use a good quality detergent motor oil that meets the api service classificatin CC or CD. Use oil of proper SAE viscosity for expected temperature conditions at the time of starting, not for the highest temperature expected during the working day.

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE) C°–34 –29

–23 –18

–13

–7

–1

+4

+10 +15

+21

+27 +32 +38

+43

+49

+54 +60

+70

+80 +90 +100 +110 +120 +130 +140

Dealer Copy -- Not for Resale

Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . .28.5 .

PSI (196,5 kPa) at 1500 RPM End Clearnace in Oil Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . .004 . . (,1 mm)

SAE 10W–30

SAE 15W–40 SAE 5W–30 SAE 30W

SAE 20W–20

SAE 10W

F°–30 –20

–10

0

+10

+20 +30

+40 +50 +60

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (GASOLINE: USE API CLASSIFICATION SE) (DIESEL: USE API CLASSIFICATION CD)

181 of 216 Revised February 80

–8B–1–

600, 600D, 610, 611 Loader Service Manual

8B–1.3 Govern, Front Cover and Throttle Distance from Governor Bearing Cup to Engine Block . . 3.37–3.38 (85,6–85,7) End Play in Throttle Shaft . . . . . . . . . . . . . . . . . . . . . . ..008–.043 .

(0,2–1,1 mm) Engine High Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2674 . . . RPM Engine Low Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 . . . RPM 8B–1.4 Cylinder Head and Valves I.D. of Valve Guides . . . . . . . . . . . . . . . . . . . . . . .315–.3155 .

(8,000–8,015 mm) I.D. of Bore for Intake Valve Seat . . . . . . . . . . . . .1.378–1.379 (35,000–35,025) I.D. of Bore for Exhaust Valve Seat . . . . . . . . . 1.5354–1.5364 (39,000–39,025) Valve Seat Width, Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..040–.055 ..

(1,0–1,4) Valve Seat Width, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . ..031–.033 .

(0,8–0,83 Valve Seat Angle, Exhaust and Intake . . . . . . . . . . . . . . . . . . . . 44–1/2° . ± 0° 10’ Valve Stem Diameter, Intake . . . . . . . . . . . . . . . . . . . ..3134–.314 (7,96–7,975) Valve Stem Diameter, Exhaust . . . . . . . . . . . . . . . . . . ..3118–.3126 .

(7,92–7,94) Maximum Distance Valves may be Recessed into Head . . . . . . . .020 (0,5 mm) Maximum Distance Valves may Protrude from Head, Exhaust . . . . . .095 (2,42) Valve Clearance, Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 . . . (0,15 mm) Minimum Free Length of Valve Springs . . . . . . . . . . . . . . . . . . . . . 1.81 .

(46 mm) Maximum Length of Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . .9.114 .

(231,5) 8B–1.5 Cylinder, Piston and Connecting Rod

Dealer Copy -- Not for Resale

Cylinder Bore (Standard) . . . . . . . . . . . . . . . . . . . 3.622–3.623 .

(92,000–92,022) Maximum Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .012 . . . (0,3 mm) Piston Diameter (Standard) . . . . . . . . . . . . . . . . 3.6197–3.620 .

(91,940–91,949) Piston Diameter (1st oversize) . . . . . . . . . . . . .3.6394–3.6397 (92,440–92,449) Piston Diameter (2nd oversize) . . . . . . . . . . . . . .3.659–3.6594 (92,940–92,949) Wrist Pin Bore . . . . . . . . . . . . . . . . . . . . . . . . . 1.1812–1.1814 ..

(30,002–30,007) Wrist Pin Diameter . . . . . . . . . . . . . . . . . . . . . . .1.1809–1.1811 .

(29,996–30,00) Piston Ring Side Clearance, Top Compression Ring . . . . . . . . . . .(0,088–0,112) Piston Ring Side Clearance, 2nd & 3rd Compression Ring . . . . . (0,090–0,122) Piston Ring Side Clearance, Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . .006 . . (0,15) Ring End Gap, Compression . . . . . . . . . . . . . . . . . . ..014–.022 .

(0,35–0,55 mm) Maximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..079 . . (2,0 mm) Distance Between Piston & Head . . . . . . . . . . . . . . . . . . . . ..031–.039 .

(0,8–1,0) Compression Pressure . . . . . . . . . . . . . . . . . . . .355–575 .

PSI (2445–3960 kPa) NOTE: The cylinders must be within 35 PSI (241 kPa) of each other .

I.D. of Hole in Connecting Rod for Wrist Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3386–1.3392 ..

(34,000–34,016) I.D. of Wrist Pin Bushing . . . . . . . . . . . . . . . . . 1.1827–1.1841 .

(30,040–30,076) I.D. of Hole in Connecting Rod for Crankshaft Bearing . . . . . . . . . . . . . . . . . . . . .2.2441–2.2448 .

(57,000–57,019) Rod–to–Crankshaft Clearance . . . . . . . . . . . . . . . . . ..002–.0044 (0,050–0,112) Rod–to–Crankshaft (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..012 . . (0,3) Rod–to–Crankshaft Side Clearance . . . . . . . . . . . . . . . .006–.012 (0,170–0,271) 8B–1.6 Camshaft, Crankshaft, Bearings Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..006–.024 ..

(0,15–0,60) Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..039 . . . .(1,0) I.D. of Camshaft Bushing . . . . . . . . . . . . . . . . . . 1.8901–1.8923 .

(48,01–48,064) Diameter of Crankpin, Standard . . . . . . . . . . . . .2.046–2.0468 (51,971–51,990) Diameter of Crankpin, 1st Undersize . . . . . . . . 2.0264–2.0272 (51,471–51,490) Diameter of Crankpin, 2nd Undersize . . . . . . . 2.0067–1.0075 (50,971–50,990) Diameter of Crankpin, 3rd Undersize . . . . . . . . 1.9870–1.9878 (50,471–50,490) Width of Crankpin . . . . . . . . . . . . . . . . . . . . . . .1.3386–1.3401 .

(34,000–34,039) Diameter of Crankshaft Main Journals Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4398–2.4406 ..

(61,971–61,990) Diameter of Crankshaft Main Journals ..

1st Undersize . . . . . . . . . . . . . . . . . . . . . . . . . 2.4201–2.4209 (61,471–61,490) Diameter of Crankshaft Main Journals 2nd Undersize . . . . . . . . . . . . . . . . . . . . . . . . .2.4004–2.4012 .

(60,971–60,990) Diameter of Crankshaft Main Journals 3rd Undersize . . . . . . . . . . . . . . . . . . . . . . . . 2.3807–2.3815 ..

(60,471–60,4900) Crankshaft Center Journal, Standard . . . . . . . . . 2.361–2.3618 (59,971–59,990) Crankshaft Center Journal, 1st Undersize . . . 2.3414–2.3421 (59,471–59,4900) Crankshaft Center Journal, 2nd Undersize . . . 2.3217–2.3224 (58,971–58,990) Crankshaft Center Journal, 3rd Undersize . . . . 2.302–2.3028 (58,471–58,490) Maximum Out–of–Round Tolerance of Journals . . . . . . . . . . . . . . . .0027 (0,07) End Play of Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..008–.016 ..

(0,2–0,4) Hardness of Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rc . . .53–60 182 of 216

–8B–2

600, 600D, 610, 611 Loader Service Manual

ITEM

PRELOADING

TIGHTENING TOTAL

Cylinder Head Bolts

21.5 ft.–lbs. (29 Nm)

30° 60° 60°

150°

Injector Hold–Down

21.5 ft.–lbs. (29 Nm)

60° 60° ––

120°

Connecting Rod

21.5 ft.–lbs. (29 Nm)

30° 60° ––

90°

Camshaft Bearing Flange

––

–– –– ––

25 ft.–lbs. (34 Nm)

Bearing Support

21.5 ft.–lbs. (29 Nm)

30° 30° ––

60°

Blower Mounting Bolts ––

–– –– ––

25 ft.–lbs. (34 Nm)

V–Belt Pulley

21.5 ft.–lbs. (29 Nm)

90° –– ––

90°

Intake Manifold

––

–– –– ––

11 ft.–lbs. (15 Nm)

Crankshaft Gear

21.5 ft.–lbs. (29 Nm)

30° 30° ––

60°

Oil Suction Pipe

––

–– –– ––

36 ft.–lbs. (49 Nm)

Flywheel

21.5 ft.–lbs. (29 Nm)

60° 30° ––

90°

Rocker Arm Bolts

21.5 ft.–lbs. (29 Nm)

45° –– ––

45°

Balance Weight

21.5 ft.–lbs. (29 Nm)

30° 30° ––

60°

8B–1.8 Special Tools (Also See Clark Tool Catalog P/N 6556519) DEUTZ P/N 100020 100030 101900 101910 110030 121100 122100 122230 122800 122970 123310 123830 124020 130300 130510 131000 139000 141000 143620 150010 150800

183 of 216

Added Dec. 78

DESCRIPTION Compression checking tool Compression checking tool Angle of turn gauge for head bolts Angle of turn gauge for other bolts Tool for nozzle removal (use with 150800) Valve spring tool Valve service tools Valve service tools Valve service tools Valve service tools Valve service tools Valve service tools Valve service tools Piston ring tool Piston ring compressor Wrist pin mandrel Heater for piston Puller for end cover and gears Tool for installing camshaft bearings Tool for reconditioning cylinder face on crankcase Puller tool

–8B–3–

Dealer Copy -- Not for Resale

8B–1.7 Torque Specifications

600, 600D, 610, 611 Loader Service Manual

600D LOADER (DEUTZ DIESEL)

54 (1372)

138 (3505) 120 (3048)

38°

31 (787)

101 (2565) 86 (2184)

45°

60 (1524)

41 (1041) 27°

79 (2007)

8 (203)

8 (203)

35 (889)

15 (381)

25°

41.5 (1054 ) 48 (1219)

34 (864)

53.5 (1359)

107 (2718)

46 (1168) PI–01458

Dimensions are given for loader equipped with dirt bucket and may vary with other bucket types. All dimensions are shown in inches. Metric dimensions are given in millimeters enclosed by parentheses.

OPERATIONAL & PERFORMANCE Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4235 . . (1921,0 kg) Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . 1000 . lbs. (453,6 kg) Lift Capacity to Maximum Height . . . . . . . . . . . . . . .1700 lbs. (771,1 kg) Tipping Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1830 .. lbs. (830,1 kg) Hydraulic Function Time: Raise to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 . sec.

Lower from Maximum Height. . . . . . . . . . . . . . . . . . . . . . . . . . .2.6 . sec.

Dumping Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 . . sec.

Rollback Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 . . sec.

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . .Infinitely . variable to 4.4 MPH (7,1 km/hr) forward & reverse Controls: Vehicle . . . . . . . . . . . . . . . . . . . . Forward, . reverse & steering functions controlled by two hand levers Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hand . elver controlled, hydraulically adjusted variable sheave.

Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift, . . tilt & auxiliary functions controlled by separate foot pedals.

Engine . . . . . . . . . . . . . . . . . . . . Handle . lever throttle, key–type starter switch & pushbutton preheater.

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Deutz ...

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F2L410 ...

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. . . .2 Diesel Governed Flywheel Horsepower . . . . . . . . . . 24 (30,5 kw) @ 2700 RPM Maximum Torque . . . . . . . . . . . . .47.4 ft.–lbs. (64,27 Nm) @ 2200 RPM Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .

Bore/Stroke . . . . . . . . . . . . . . . . . . . 3.59x3.94 . in. (91,186x100,076 mm) Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . 77.6 . . cubic inches (1,3L) Cooling Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air ...

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure ..

Lubrication Filtration . . . . . . . Replacement element, full flow w/by–pass Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . Filtered .

Road Vent Air Cleaner . . . . . . Replaceable dry cartridge type w/condition indicator Preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 . . volt glow plug 184 of 216 80 Revised February

65 (1651)

Where applicable, specifications conform t o ICED & SAE standards and are subject to change without notice.

LOADER HYDRAULICS Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine .. driven, gear type Minimum Pump Capacity . . . . . . . . . . . . 8.7 GPM (33L/M) @ 2700 RPM System Relief Setting . . . . . . . . . . . . . . . . . . . . . . 1700 PSI (11721 kPa) .

Filtration . . . . . . . . . . . . Full flow on suction side with by–pass, condition indicator & 33 micron replaceable element Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Doubleacting ..

Function Lift Tilt 2.00’’ (50,80 mm) 2.00’’ (50,80 mm) Bore Diameter Rod Diameter 1.25’’ (31,75 mm) 1.00’’ (25,4 mm) Stroke 25.90’’ (658,00 mm) 16.60’’ (422,00 mm) Valves . . . . . . . . . . . . . . . . . . . Open–center . type with float detent on lift ELECTRICAL .

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .Enclosed belt driver 22 amp.

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 . . volt 70 amp.–hr. rating Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . volt gear drive DRIVE SYSTEM Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Variable . sheave type Clutches . . . . . . . . . . . . . .4 (2 each side) single disc pressure lubricated Primary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45:1 .. ratio Secondary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.00:1 .. ratio Final Drive . . . . . . . . . . . . . . #60H roller chain running in sealed oil bath Total Engine to Wheel Reduction . . . . . Variable from 37:1 to 100:1 ratio CAPACITIES Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5 . . gal (39,7 L) Engine Lubricant Including Filter . . . . . . . . . . . . . . . . . . . . . . 4. qt. (3,8 L) Hydraulic Reservoir & Final Drive Case . . . . . . . . . . . . . . 17 gal. (64,4 L) Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 . gal. (75,7 L) TIRES Standard . . . . 7:00x15–6 ply nylon steel cap w/Melroe special bar tread Pressure . . . . . . . . . . . . . . . . . . . . . .45–50 .

PSI (310,275–344,750 kPa) COUNTERWEIGHT Standard Cast Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 . lbs. (45,4 kg) Ballast (If Any) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320 . . lbs. (140 kg) MACHINE WEIGHT (Less Bucket) Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3805 . . lbs. (1726,0 kg)

–8B–4

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

17.75 (450)

81.7 (2075)

108 (2743)

611 LOADER (DEUTZ DIESEL)

54 (1372)

138 (3505) 120 (3048)

38°

31 (787)

101 (2565) 86 (2184)

45°

60 (1524)

41 (1041) 27°

79 (2007)

8 (203)

8 (203)

35 (889)

15 (381)

25°

41.5 (1054 ) 48 (1219)

34 (864)

53.5 (1359)

107 (2718)

46 (1168) PI–01458

Dimensions are given for loader equipped with dirt bucket and may vary with other bucket types. All dimensions are shown in inches. Metric dimensions are given in millimeters enclosed by parentheses.

OPERATIONAL & PERFORMANCE Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4200 .

(1900 kg) Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . 1000 . lbs. (453,6 kg) Lift Capacity to Maximum Height . . . . . . . . . . . . . . .1700 lbs. (771,8 kg) Tipping Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2100 . . lbs. (950 kg) Hydraulic Function Time: Raise to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 . sec.

Lower from Maximum Height. . . . . . . . . . . . . . . . . . . . . . . . . . .2.6 . sec.

Dumping Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 . . sec.

Rollback Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 . . sec.

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . .Infinitely . variable to 6.4 MPH (10,3 km/hr) forward & reverse Controls: Vehicle . . . . . . . . . . . . . . . . . . . . Forward, . reverse & steering functions controlled by two hand levers Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hand . elver controlled, hydraulically adjusted variable sheave.

Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift, . . tilt & auxiliary functions controlled by separate foot pedals.

Engine . . . . . . . . . . . . . . . . . . . . Handle . lever throttle, key–type starter switch & pushbutton preheater.

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Deutz ...

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F2L411 ...

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. . . .2 Diesel Governed Flywheel Horsepower . . . . . . . . . 27.5 (20,5 kw) @ 2700 RPM Maximum Torque . . . . . . . . . . . . . . . . .58 ft.–lbs. (79 Nm) @ 2000 RPM Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . 3.62x4.13 . in. (91,95x104,90 mm) Displacement . . . . . . . . . . . . . . . . . . . . . . . .85.2 . cubic inches (1,396 L) Cooling Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air ...

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure ..

Lubrication Filtration . . . . . . . Replacement element, full flow w/by–pass Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . Filtered .

Road Vent Air Cleaner . . . . . . Replaceable dry cartridge type w/condition indicator Preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 . . volt glow plug 185 of 216 Revised February 80

65 (1651)

Dealer Copy -- Not for Resale

17.75 (450)

81.7 (2075)

108 (2743)

Where applicable, specifications conform t o ICED & SAE standards and are subject to change without notice.

LOADER HYDRAULICS Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine .. driven, gear type Minimum Pump Capacity . . . . . . . . . . . . .8.7 GPM (32,1L) @ 2700 RPM System Relief Setting . . . . . . . . . . . . . . . . . . . . . . 1700 PSI (11721 kPa) .

Filtration . . . . . . . . . . . . Full flow on suction side with by–pass, condition indicator & 33 micron replaceable paper element Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Doubleacting ..

Function Lift Tilt 2.00’’ (50,80 mm) 2.00’’ (50,80 mm) Bore Diameter Rod Diameter 1.25’’ (31,75 mm) 1.00’’ (25,4 mm) Stroke 25.90’’ (657,86 mm) 16.50’’ (419,10 mm) Valves . . . . . . . . . . . . . . . . . . . Open–center . type with float detent on lift ELECTRICAL .

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .Enclosed belt driver 22 amp.

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 . . volt 70 amp.–hr. rating Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . volt gear drive DRIVE SYSTEM Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Variable . sheave type Clutches . . . . . . . . . . . . . .4 (2 each side) single disc pressure lubricated Primary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45:1 .. ratio Secondary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.00:1 .. ratio Final Drive . . . . . . . . . . . . . . #60H roller chain running in sealed oil bath Total Engine to Wheel Reduction . . . . . Variable from 37:1 to 100:1 ratio CAPACITIES Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.gal . (26 L) Engine Lubricant Including Filter . . . . . . . . . . . . . . . . . . . . . . 4. qt. (3,8 L) Hydraulic Reservoir & Final Drive Case . . . . . . . . . . . . . . 17 gal. (64,4 L) Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 . gal. (75,7 L) TIRES Standard . . . . . . . . . . . . . . . . . . . . . . . . . .7:00x15–6 . ply nylon steel cap Pressure . . . . . . . . . . . . . . . . . . . . . .45–50 .

PSI (310,275–344,750 kPa) COUNTERWEIGHT Standard Cast Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 . lbs. (45,4 kg) Ballast (If Any) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320 . . lbs. (140 kg) MACHINE WEIGHT (Less Bucket) Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3800 . . lbs. (1700 kg)

–8B–5–

600, 600D, 610, 611 Loader Service Manual

611D LOADER (BUREAU OF MINES APPROVED) 610,611ServiceManual#6556276–Specifications(Deutz)SectionPart2of5

54 (1372)

135.5 (3442) 120 (3048)

38°

31 (787)

101 (2565) 86 (2184)

45°

60.25 (1530)

41 (1041) 21°

84.25 (2140)

8 (203)

87.5(191)

35 (889)

15 (381)

25°

42 (1067) 51.25 (1302)

34 (864)

53.5 (1359)

108.25 (2750)

46 (1168) PI–01458

Dimensions are given for loader equipped with dirt bucket and may vary with other bucket types. All dimensions are shown in inches. Metric dimensions are given in millimeters enclosed by parentheses.

OPERATIONAL & PERFORMANCE Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4326 . . (1962,0 kg) Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . 1000 . lbs. (453,6 kg) Lift Capacity to Maximum Height . . . . . . . . . . . . . . .2193 lbs. (994,7 kg) Tipping Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2560 . . lbs. (1161 kg) Hydraulic Function Time: Raise to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6 . sec.

Lower from Maximum Height. . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 . sec.

Dumping Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 . . sec.

Rollback Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 . . sec.

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . .Infinitely . variable to 6.4 MPH (10 km/hr) forward & reverse Controls: Vehicle . . . . . . . . . . . . . . . . . . . . Forward, . reverse & steering functions controlled by two hand levers Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hand . lever controlled, hydraulically adjusted variable sheave.

Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift, . . tilt & auxiliary functions controlled by separate foot pedals.

Engine . . . . . . . . . . . . . . . . . . . . Handle . lever throttle, key–type starter switch & pushbutton preheater.

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Deutz ...

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F2L411W ...

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. . . .2 Diesel Governed Flywheel Horsepower . . . . . . . . . 22.5 (16,8 kw) @ 2700 RPM Maximum Torque . . . . . . . . . . . . . . . . .53 ft.–lbs. (72 Nm) @ 2200 RPM Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . 3.62x4.13 . in. (91,9x104,90 mm) Displacement . . . . . . . . . . . . . . . . . . . . . . . .85.2 . cubic inches (1,396 L) Cooling Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air ...

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure ..

Lubrication Filtration . . . . . . . Replacement element, full flow w/by–pass Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . Filtered .

Road Vent Air Cleaner . . . . . . Replaceable dry cartridge type w/condition indicator Preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 . . volt glow plug 186 of 216 80 Revised February

65 (1651)

Where applicable, specifications conform t o ICED & SAE standards and are subject to change without notice.

LOADER HYDRAULICS Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine .. driven, gear type Minimum Pump Capacity . . . . . . . . . . .8.7 GPM (33,1 L/M @ 2700 RPM System Relief Setting . . . . . . . . . . . . . . . . . . . . . . 1700 PSI (11721 kPa) .

Filtration . . . . . . . . . . . . Full flow on suction side with by–pass, condition indicator & 33 micron replaceable paper element Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Doubleacting ..

Function Lift Tilt 2.00’’ (50,80 mm) 2.00’’ (50,80 mm) Bore Diameter Rod Diameter 1.25’’ (31,75 mm) 1.00’’ (25,4 mm) Stroke 25.90’’ (658,00 mm) 16.60’’ (421,64 mm) Valves . . . . . . . . . . . . . . . . . . . Open–center . type with float detent on lift ELECTRICAL Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .Enclosed . belt driver 22 amp.

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 . . volt 70 amp.–hr. rating Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . volt gear drive DRIVE SYSTEM Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Variable . sheave type Clutches . . . . . . . . . . . . . .4 (2 each side) single disc pressure lubricated Primary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45:1 .. ratio Secondary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.00:1 .. ratio Final Drive . . . . . . . . . . . . . . #60H roller chain running in sealed oil bath Total Engine to Wheel Reduction . . . . . Variable from 37:1 to 100:1 ratio CAPACITIES Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.gal . (30 L) Engine Lubricant Including Filter . . . . . . . . . . . . . . . . . . . . . . 4. qt. (3,8 L) Hydraulic Reservoir & Final Drive Case . . . . . . . . . . . . . . 17 gal. (64,4 L) Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 . gal. (75,7 L) TIRES Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10x16.5–6 .. ply Pressure . . . . . . . . . . . . . . . . . . . . . .30–35 .

PSI (206,850–241,325 kPa) COUNTERWEIGHT Front Mounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170 . lbs. (77,1 kg) Scrubber Muffler Filled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE WEIGHT (Less Attachments) Shipping (W/Scrubber Muffler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

–8B–6

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

17.50 (445)

82 (2083)

108 (2743)

ENGINE SPECIFICATIONS (PETTER) Paragraph Page Number Number ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–1 ..

8C–1 LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8C–6

Dealer Copy -- Not for Resale

PETTER

187 of Dec. 216 78 Added

–8C––1–

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale 188 of 216

–8C–0

600, 600D, 610, 611 Loader Service Manual

8C–1 ENGINE SPECIFICATIONS (Petter) All specifications are given in inches with metric parentheses.

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 . . .CID (1147 cc) Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5 . . .(88,9) .

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.625 . . . (92,1) Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–2 ....

Oil Capacity W/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–1/2 .. gal. (5,2 L) 8C–1.1 Fuel Specifications Always use clean fuel. Do not let the fuel tank become empty.

Type of Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. . . . 2 Diesel Fuel 8C–1.2 Engine Oil System: Check oil level after every 8 hours of operation. (Check oil every 4 hours on new engine during the first 50 hours of operation).

Oil level must be maintained between the add and full mark on the dipstick.

Use a good quality detergent motor oil that meets the correct API service classification SE. Use oil of proper SAE viscosity for expected temperature conditions at the time of starting, not for the highest temperature expected during the working day.

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE) C°–34 –29

–23 –18

–13

–7

–1

+4

+10 +15

+21

+27 +32 +38

+43

+49

+54 +60

+70

+80 +90 +100 +110 +120 +130 +140

SAE 10W–30

SAE 15W–40

Dealer Copy -- Not for Resale

Specifications:

SAE 5W–30 SAE 30W

SAE 20W–20

SAE 10W

F°–30 –20

–10

0

+10

+20 +30

+40 +50 +60

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (GASOLINE: USE API CLASSIFICATION SE) (DIESEL: USE API CLASSIFICATION CD)

Lubrication System Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 . . PSI (310,27 kPa) Lubrication Filtration . . . . . . . . . . . . . .Replaceable element, full flow w/by–pass

189 of 216 Revised February 80

–8C–1–

600, 600D, 610, 611 Loader Service Manual

8C–1.3 Cylinder Head Valve Guide Bore Diameter . . . . . . . . . . . . . . . . . . . 0.312–0.313 .

(7,924–7,950) Valve Depth From Cylinder Head Face (New) . . . . 0.028–0.053 (0,711–1,346) 8C–1.4 Valve Mechanism Valve Rocker Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.004 .

(0,101) Exhaust Valve Lift By Decompressor (Max.) . . . . . . . . . . . . . . . . . .0.025 (0,635) Bumping Clearance . . . . . . . . . . . . . . . . . . . . . . . .0.032–0.037 .

(0,812–0,939) 8C–1.5 Camshaft Camshaft End Float . . . . . . . . . . . . . . . . . . . . . . . .0.003–0.015 .

(0,0762–0,381) Intake Valve Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5° . . . before TDC Intake Valve Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38.5° . . after BDC Exhaust Valve Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.5° . . . before BDC Exhaust Valve Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.5° .. after TDC 8C–1.6 Crankshaft Crankshaft End Float (New) . . . . . . . . . . . . . . .0.0075–0.0185 (0,1905–0,4699) Crankshaft End Float (Not To Exceed) . . . . . . . . . . . . . . . . . . . . . 0.025 .

(0,635) Crankshaft Out–Of–Round (Not to Exceed) . . . . . . . . . . . . . . . . .0.003 (0,0762) Main Bearing Clearance (New) . . . . . . . . . . . .0.0012–0.0028 (0,0304–0,07112) Connecting Rod Bearing Clearance . . . . . . . . . 0.0015–0.0030 (0,0381–0,0762)

Main Journal

Intermediate Journal

Crankpin

2.9995–2.990 (76,1863–76,1746)

2.7485–2.7480 (69,8119–69,7992)

2.1250–2.1245 (53,975–53,9623)

0.010 (0,254)

2.9895–2.9890 (5,9333–75,9206)

2.7385–2.7380 (69,5579–69,5452)

2.1150–2.1145 (53,721–53,7083)

0.020 (0,508)

2.9795–2.9790 (75,6793–75,6666)

2.7285–2.7280 (69,3039–69,2912)

2.1050–2.1045 (53,467–53,4543)

0.030 (0,762)

2.9695–2.9690 (75,4253–75,4126)

2.7185–2.7180 (69,0499–69,0372)

2.0950–2.0945 (53,213–53,2003)

0.040 (1,016)

2.9595–2.9590 (75,1713–75,1586)

2.7085–2.7080 (68,7959–68,7832)

2.0850–2.0845 (52,959–52,9463)

Standard

Dealer Copy -- Not for Resale

Crankshaft Regrinding Diameters:

Undersize:

8C–1.7 Connecting Rod Connecting Rod Bearing Clearance . . . . . . . . . 0.0025–0.0030 (0,0381–0,0762) Connecting Rod Small Bushing Diameter (Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1253–1.1258 ..

(28,5826–28,5953) 8C–1.8 Piston Piston Ring Gap (New) . . . . . . . . . . . . . . . . . . . . . . . 0.010–0.015 .

(0,254–0,381) Piston Ring Gap (Not To Exceed) . . . . . . . . . . . . . . . . . . . . . . . . . .0.040 .

(1.016) 8C–1.9 Cylinder Block Cylinder Bore Wear (Not To Exceed) . . . . . . . . . . . . 0.010–0.015 (0,254–0,381) Cylinder Reboring Diameters: Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.500–3.501 ..

(88,9–88,925) Oversize: 0.20 (0,508) . . . . . . . . . . . . . . . . . . . . . . . . . 3.5200–3.5210 ..

(89,408–89,4334) 0.040 (1,016) . . . . . . . . . . . . . . . . . . . . . . . . 3.5400–3.5410 ..

(89,916–89,9414)

190 of 216

–8C–2

600, 600D, 610, 611 Loader Service Manual

8C–1.10 Torque Specifications

Dealer Copy -- Not for Resale

Connecting Rod Cap Bolts . . . . . . . . . . . . . . . . . . . . . . . .40 . ft.–lbs. (54,233 Nm) Cylinder Head Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . ft.–lbs. (46,098 Nm) Injector Mounting Stud Nuts . . . . . . . . . . . . . . . . . . . . . . 15 . ft.–lbs (20,337 Nm) Lubricating Oil Filter Bolt . . . . . . . . . . . . . . . . . . . . . . . . .10 . ft.–lbs. (13,558 Nm) Fuel Filter Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 . . ft.–lbs. (13,558 Nm) Flywheel Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 . . ft.–lbs. (47,454 Nm) Crankshaft Gear Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . . ft.–lbs. (47,454 Nm) Camshaft Gear Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . ft.–lbs. (33,895 Nm) Flywheel End Extension Shaft Bolt . . . . . . . . . . . . . . . . . 25 . ft.–lbs. (33,895 Nm) Camshaft Extension Shaft Bolt . . . . . . . . . . . . . . . . . . . .35 . ft.–lbs. (47,454 Nm) Rocker Support Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 . ft.–lbs (20,337 Nm) Center Main Bearing Bolt . . . . . . . . . . . . . . . . . . . . . . . . .25 . ft.–lbs. (33,895 Nm)

191 of 216 Added Dec. 78

–8C–3–

600, 600D, 610, 611 Loader Service Manual

600D LOADER (DEUTZ DIESEL) 610,611ServiceManual#6556276–Specifications(Petter)SectionPart3of5

54 (1372)

138 (3505) 120 (3048)

38°

31 (787)

101 (2565) 86 (2184)

45°

60 (1524)

41 (1041) 27°

79 (2007)

8 (203)

8 (203)

35 (889)

15 (381)

25°

41.5 (1054 ) 48 (1219)

34 (864)

53.5 (1359)

107 (2718)

46 (1168) PI–01458

Dimensions are given for loader equipped with dirt bucket and may vary with other bucket types. All dimensions are shown in inches. Metric dimensions are given in millimeters enclosed by parentheses.

OPERATIONAL & PERFORMANCE Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4255 .

(1930 kg) Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . 1000 . lbs. (453,6 kg) Lift Capacity to Maximum Height . . . . . . . . . . . . . . .1700 lbs. (771,8 kg) Tipping Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1830 .. lbs. (830,1 kg) Hydraulic Function Time: Raise to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 . sec.

Lower from Maximum Height. . . . . . . . . . . . . . . . . . . . . . . . . . .2.7 . sec.

Dumping Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 . . sec.

Rollback Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 . . sec.

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . .Infinitely . variable to 5.7 MPH (9,2 km/hr) forward & reverse Controls: Vehicle . . . . . . . . . . . . . . . . . . . . Forward, . reverse & steering functions controlled by two hand levers Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hand . lever controlled, hydraulically adjusted variable sheave.

Loader . . . . . . . . . . . . . . . . . . . . Lift, . tilt & auxiliary functions controlled by separate foot pedals.

Engine . . . . . . . . . . . . . . .Handle lever throttle, key–type starter switch ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Petter ...

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BA2R ...

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No. . . .2 Diesel Governed Flywheel Horsepower . . . . . . . . . . 25 (25,4 kw) @ 3000 RPM Maximum Torque . . . . . . . . . . . . . . 43 . ft.–lbs. (58,30 Nm) @ 2400 RPM Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . 3.500x3.625 . in. (88,9x92,075 mm) Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 . cubic inches (1,2L) Cooling Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air ...

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure ..

Lubrication Filtration . . . . . . . Replacement element, full flow w/by–pass Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . Internal . breathing Air Cleaner . . . . . . Replaceable dry cartridge type w/condition indicator

192 of78 216 Revised Dec.

65 (1651)

Where applicable, specifications conform t o ICED & SAE standards and are subject to change without notice.

LOADER HYDRAULICS Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Belt . . driven, gear type Minimum Pump Capacity . . . . . . . . . . .8.7 GPM (33,0 L/M @ 3000 RPM System Relief Setting . . . . . . . . . . . . . . . . . . . . . . 1700 PSI (11721 kPa) .

Filtration . . . . . . . . . . . . Full flow on suction side with by–pass, condition indicator & 33 micron replaceable paper element Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Doubleacting ..

Function Lift Tilt 2.00’’ (50,80 mm) 2.00’’ (50,80 mm) Bore Diameter Rod Diameter 1.25’’ (31.75 mm) 1.00’’ (25,4 mm) Stroke 25.90’’ (658,00 mm) 16.60’’ (422,00 mm) Valves . . . . . . . . . . . . . . . . . . . Open–center . type with float detent on lift ELECTRICAL . . driven dustproof 22 amp.

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . Belt Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 . . volt 70 amp.–hr. rating Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . volt gear drive DRIVE SYSTEM Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Variable . sheave type Clutches . . . . . . . . . . . . . .4 (2 each side) single disc pressure lubricated Primary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.00:1 .. ratio Secondary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.00:1 .. ratio Final Drive . . . . . . . . . . . . . . #60H roller chain running in sealed oil bath Total Engine to Wheel Reduction . . . . . Variable from 37:1 to 100:1 ratio CAPACITIES Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . .gal (41,6 L) Engine Lubricant Including Filter . . . . . . . . . . . . . . . . . . . .10.5 . pt. (5,0 L) Hydraulic Reservoir & Final Drive Case . . . . . . . . . . . . . . 17 gal. (64,4 L) Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 . gal. (75,7 L) TIRES Standard . . . . 7:00x15–6 ply nylon steel cap w/Melroe special bar tread COUNTERWEIGHT Standard Cast Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 . lbs. (45,4 kg) Ballast (If Any) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320 . . lbs. (140 kg) MACHINE WEIGHT (Less Bucket) Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3835 . . lbs. (1739,6 kg)

–8C–4

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

17.75 (450)

81.7 (2075)

108 (2743)

MOTOR SPECIFICATIONS, (ELECTRIC) Paragraph Page Number Number MOTOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D–1 ..

8D–1 LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8D–1

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ELECTRIC

193 of Dec. 216 78 Added

–8D––1–

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale 194 of 216

–8D–0

600, 600D, 610, 611 Loader Service Manual

600E LOADER (RELIANCE ELECTRIC)

135.5 (3442)

54 (1372)

120 (3048) 38°

108 (2743)

17.5 (445)

101 (2565)

31 (787)

82 (2083)

86 (2184)

45° 41 (1041)

27°

79 (2007)

8 (203)

87.5(191) 25°

35 (889)

15 (381)

48 (1219)

34 (864) 46 (1168) 53.5 (1359)

107 (2718)

PI–01459

Dimensions are given for loader equipped with dirt bucket and may vary with other bucket types. All dimensions are shown in inches. Metric dimensions are given in millimeters enclosed by parentheses.

OPERATIONAL & PERFORMANCE Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3550 .

(1610 kg) Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . 1000 . lbs. (453,6 kg) Lift Capacity to Maximum Height . . . . . . . . . . . . . . .1700 lbs. (771,8 kg) Tipping Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1840 . . lbs. (835 kg) Hydraulic Function Time: Raise to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.25 . sec.

Lower from Maximum Height. . . . . . . . . . . . . . . . . . . . . . . . . .3.25 . sec.

Dumping Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.75 . . sec.

Rollback Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.75 . . sec.

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . .Infinitely . variable to 3.0 MPH (4,8 km/hr) forward & reverse Controls: Vehicle . . . . . . . . . . . . . . . . . . . . Forward, . reverse & steering functions controlled by two hand levers Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hand . lever controlled, hydraulically adjusted variable sheave.

Loader . . . . . . . . . . . . . . . . . . . . Lift, . tilt & auxiliary functions controlled by separate foot pedals.

Motor . . . . . . . . . . . . . . . . . . . . . . . . . . .Pushbutton . start & stop switch MOTOR (Motor Manufacturer’s Rating) Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Reliance ...

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEFC–XP ..

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . Explosion ..

Proof Enclosure 254T Rated Horsepower . . . . . . . . . . . . . . . . . . . . . . . . 15 . (11 kw) continuous Breakdown Torque . . . . . . . . . . . . . . . . . . . . . . . .440 . volt: @ 1760 RPM 380 volt: @ 1465 RPM 550 volt: @ 1760 RPM Operating Voltage . . . . . . . . . . . . . . . . . . . . . . . . .440 . 3 phrase–60 cycle 380 3 phrase–50 cycle 550 3 phrase–60 cycle Motor Classification Rating . . . . . . . . . . . . . . . . . . . . .Class .

1–Group D; Class 2–Group E, F & G Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NEMA .. ’’A’’ Class ’’F’’ Cooling Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air ...

Cable Reel . . . . . . . . . . . . . . . . . . .Automatic retractable explosion proof Cable & Size . . . . . . . . . . . . . . . . . . . . . . . .50 . ft. (15,2 m) 10 gauge wire 195 of 216 Revised Dec. 78

42 (1067)

Dealer Copy -- Not for Resale

88 (2235)

65 (1651)

Where applicable, specifications conform t o ICED & SAE standards and are subject to change without notice.

LOADER HYDRAULICS Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Belt . . driven, gear type Minimum Pump Capacity . . . . . . . . . . . .7.5 GPM (28 L/M) @ 1750 RPM System Relief Setting . . . . . . . . . . . . . . . . . . . . . . 1700 PSI (11721 kPa) .

Filtration . . . . . . . . . . . . Full flow on suction side with by–pass, condition indicator & 33 micron replaceable paper element Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Doubleacting ..

Function Lift Tilt Bore Diameter 2.00’’ (50,80 mm) 2.00’’ (50,8 mm) Rod Diameter 1.25’’ (31.75 mm) 1.00’’ (25,4 mm) Stroke 25.90’’ (635,00 mm) 16.60’’ (406,4 mm) Valves . . . . . . . . . . . . . . . . . . . Open–center . type with float detent on lift POWER TRAIN Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Variable . sheave type Clutches . . . . . . . . . . . . . .4 (2 each side) single disc pressure lubricated Primary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.00:1 .. ratio Secondary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.00:1 .. ratio Final Drive . . . . . . . . . . . . . . #60H roller chain running in sealed oil bath Total Engine to Wheel Reduction . . . . . Variable from 36:1 to 100:1 ratio CAPACITIES Hydraulic Reservoir & Final Drive Case . . . . . . . . . . . . . . 17 gal. (64,4 L) Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 . gal. (75,7 L) TIRES Standard . . . . . . . . . . . . . 7:00x15–6 . ply nylon steel cap w/bar lug tread COUNTERWEIGHT Standard Cast Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 . . lbs. (45 kg) MACHINE WEIGHT (Less Attachment) Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3515 . . lbs. (1594 kg) Shipping (Less Reel & Cable) . . . . . . . . . . . . . . . . . . 2935 . lbs. (1331 kg)

–8D–1–

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610,611ServiceManual#6556276–Specifications(Electric)SectionPart4of5

196 of 216

–8D–2

600, 600D, 610, 611 Loader Service Manual

TECHNICAL DATA Paragraph Page Number Number DECIMAL & MILLIMETER EQUIVALENTS . . . . . . . . . . . . . . .

8E–3 HYDRAULIC/HYDROSTATIC TRANSMISSION FLUID . . . . . 8E–2 8E–1 LOADER TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . 8E–1 .

8E–1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8E–3 ..

8E–1 STANDARD TORQUE SPECIFICATIONS FOR BOLTS . . . .

8E–2 U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . . . . . . . . .

8E–3

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TECHNICAL DATA

197 of Dec. 216 78 Added

–8E––1–

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Dealer Copy -- Not for Resale 198 of 216

–8E–0

600, 600D, 610, 611 Loader Service Manual

8E–1 LOADER TORQUE SPECIFICATIONS The following special torques must be used on the Bobcat.

Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105–115 .. ft.–lbs. (102–119 Nm) Hydraulic Fluid Filter Container Nut . . . . . . . . . . . . . . . . . 12 . ft.–lbs. (16,27 Nm) Split Jackshaft Connector Screws . . . . . . . . . . . . . . . . . 20 . ft.–lbs. (27,116 Nm) Clutch Sprocket Screws . . . . . . . . . . . . . . . . . . . . . . . . . 16 . . ft.–lbs. (21,696 Nm) Upper Jackshaft Locking Collar Set Screws . . . . . . . . . .25 ft.–lbs. (33,895 Nm) Gearcase Cover Mounting Nuts . . . . . . . . . . . . . . . . . . . 30 . ft.–lbs. (40,675 Nm) Tapered Bore Drive Sheave to Crankshaft . . . . . . . . . . .35 ft.–lbs. (47,454 Nm) Lower Jackshaft (Large) Sprocket to Cluster Sprocket . . 55 ft.–lbs. (74,57 Nm) Axle Hub Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 65 . . ft.–lbs. (88,128 Nm) Upper Jackshaft Bearing Mounting Nuts . . . . . . . . . . . . .70 ft.–lbs. (94,907 Nm) Upright Brace Mounting Nuts . . . . . . . . . . . . . . . . . . . .80 . ft.–lbs. (108,465 Nm) 1/2;; Inside Clutch Chain Tightener Nuts . . . . . . . . . . . .85 ft.–lbs. (115,245 Nm) 9/16’’ Inside Clutch chain Tightener Nuts . . . . . . . . . .110 ft.–lbs. (149,140 Nm) Wheel Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . .110 . ft.–lbs. (149,140 Nm) Lower Jackshaft Mounting Screws . . . . . . . . . . . . . . . 110 . ft.–lbs. (149,140 Nm) Variable Speed Drive Sheave Retaining Nut . . . . . . . .130 ft.–lbs. (172,256 Nm) Upright Mounting Screws . . . . . . . . . . . . . . . . . . . . . . .150 . ft.–lbs. (203,373 Nm) Clutch Pin Holding Nuts . . . . . . . . . . . . . . . . . . . . . . . 225 . . ft.–lbs. (305,059 Nm) Axle Sprocket Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 . . . ft.–lbs. (610 Nm)

The hydraulic system capacity is 20 gals. (75,7 L). The loader hydraulic system reservoir must be filled only with fluid which will protect the components.

For operation in temperatures from below freezing up to hot climate conditions, use 10W–30 or 10W–40 engine oil which meets API Classification SE as replacement fluid.

Where below zero temperatures are common, loaders must be kept in warm building. Extra warm–up time must be used each time the loader is started during very cold temperature conditions. Cold oil will not flow easily, and makes action of the hydraulic components slower.

8E–3 Special Tools The special tools for the loader can be ordered from the T 6556519).

199 of February 216 Revised 80

ool Catalog (P/N

–8E–1–

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8E–2 Hydraulic Fluid

600, 600D, 610, 611 Loader Service Manual

FRACTIONS 1/64

1/32

3/64

1/16

5/64

3/32

7/64

1/8

9/64

5/32

11/64

3/16

13/64

7/32

15/64

1/4

17/64

9/32

19/64

5/16

21/64

11/32

23/64

3/8

25/64

13/32

27/64

7/16

29/64

15/32

31/64

1/2

DECIMALS

MM

0.015625 — 0.03125 — 0.046875 — 0.0625 — 0.078125 — 0.09375 — 0.109375 — 0.1250 — 0.140625 — 0.15625 — 0.171875 — 0.1876 — 0.203125 — 0.21875 — 0.234375 — 0.2500 — 0.265625 — 0.28125 — 0.296875 — 0.3125 — 0.328125 — 0.34375 — 0.359375 — 0.3750 — 0.390625 — 0.40625 — 0.421875 — 0.4375 — 0.453125 — 0.46875 — 0.484375 — 0.5000 —

0.397 0.794 1.191 1.588 1.984 2.381 2.778 3.175 3.572 3.969 4.366 4.762 5.159 5.556 5.953 6.350 6.747 7.144 7.541 7.938 8.334 8.731 9.128 9.525 9.922 10.319 10.716 11.112 11.509 11.906 12.303 12.700

FRACTIONS 17/32 9/16 19/32 5/8 21/32 11/16 23/32 3/4 25/32 13/16 27/32 7/8 29/32 15/16 31/32 1

1 mm = 0.03937’’

33/64 35/64 37/64 39/64 41/64 43/64 45/64 47/64 49/64 51/64 53/64 55/64 57/64 59/64 61/64 63/64

DECIMALS

MM

0.515625 — 0.53125 — 0.546875 — 0.5625 — 0.578125 — 0.59375 — 0.609375 — 0.6250 — 0.640625 — 0.65625 — 0.671875 — 0.6875 — 0.703125 — 0.71875 — 0.734375 — 0.7500 — 0.765625 — 0.78125 — 0.796875 — 0.8125 — 0.828125 — 0.84375 — 0.859375 — 0.8750 — 0.890625 — 0.90625 — 0.921875 — 0.9375 — 0.953125 — 0.96875 — 0.984375 — 1.000 —

13.097 13.494 13.891 14.288 14.684 15.081 15.478 15.875 16.272 16.669 17.066 17.462 17.859 18.256 18.653 19.050 19.447 19.844 20.241 20.638 21.034 21.431 21.828 22.225 22.622 23.019 23.416 23.812 24.209 24.606 25.003 25.400

0.001 = 0.0254 mm

U.S. TO METRIC CONVERSION TO CONVERT

INTO

LINEAR MEASUREMENT

Miles Yards Feet Feet Inches Inches Inches

Kilometers Meters Meters Centimeters Meters Centimeters Millimeters

1.609 0.9144 0.3048 30.48 0.0254 2.54 25.4

AREA

Square Miles Square Feet Square Inches Acre

Square Kilometers Square Meters Square Centimeters Hectare

2.59 0.0929 6.452 0.4047

VOLUME

Cubic Yards Cubic Feet Cubic Inches

Cubic Meters Cubic Meters Cubic Centimeters

0.7646 0.02832 16.39

WEIGHT

Tons (Short) Pounds Ounces (Avdp.)

Metric Tons Kilograms Grams

0.9078 0.4536 28.3495

PRESSURE

Pounds/Sq. In.

Kilopascal

6.895

WORK

Foot–Pounds

Newton–Meter

1.356

LIQUID VOLUME

Quarts Gallons

Liters Liters

0.9463 3.785

LIQUID FLOW

Gallons/Minute

Liters/Minute

3.785

TEMPERATURE

Fahrenheit

Celsius

Added Dec.200 78of 216

MULTIPLY BY

1.Subtract 32° 2. Multiply by 5/9 –8E–2

600, 600D, 610, 611 Loader Service Manual

Dealer Copy -- Not for Resale

DECIMAL AND MILLIMETER EQUIVALENTS

STANDARD TORQUE SPECIFICATIONS FOR BOLTS

THREAD SIZE

SAE GRADE 5

SAE GRADE 8

0.250

80–90 (9–10)

110–120 (13–14)

0.3125

180–200 (21–23)

215–240 (24–27)

0.375

25–28 (34–38)

35–40 (48–54)

0.4375

40–45 (54–61)

60–65 (82–88)

0.500

65–70 (88–95)

90–100 (125–135)

0.5625

90–100 (125–135)

125–140 (170–190)

0.625

125–140 (170–190)

175–190 (240–260)

0.750

220–245 (300–330)

300–330 (410–450)

0.875

330–360 (450–490)

475–525 (645–710)

1.000

475–525 (645–710)

725–800 (985–1085)

1.125

650–720 (880–975)

1050–1175 (1425–1600)

1.250

900–1000 (1200–1360)

1475–1625 (2000–2200)

1.375

1200–1350 (1630–1830)

2000–2200 (2720–2980)

1.500

1500–1650 (2040–2240)

2600–2850 (3530–3870)

1.625

2000–2800 (2720–2980)

3450–3800 (4680–5150)

1.750

2500–2750 (3390–3730)

4300–4800 (5830–6500)

1.875

3150–3500 (4270–4750)

5500–6100 (7450–8300)

2.000

3800–4200 (5150–5700)

6500–7200 (8800–9800)

INCH. LBS. (Nm)

FOOT LBS. (Nm)

201 of 216

–8E–3–

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The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from Clark that have zinc phosphate coating are specified by the letter H following the part number.

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610,611ServiceManual#6556276–SpecificationsSectionPart5of5

202 of 216

–8E–4

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GENERAL SERVICE Page Number 9–1

Dealer Copy -- Not for Resale

Paragraph Number ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 ..

ALPHABETICAL INDEX

203 of 216

–9––1–

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–9–0

600, 600D, 610, 611 Loader Service Manual

ALPHABETICAL INDEX PAGE

Accessories, installation . . . . . . . . . . . . . . . . . . . . . .5–18 .

Accessories, removal . . . . . . . . . . . . . . . . . . . . . . . .5–11 .

Air Cleaner, engine . . . . . . . . . . . . . . . . . . . . . . . . . . .1–4 .

Air Cleaner, heavy duty . . . . . . . . . . . . . . . . . . . . . . .1–4 .

Air Cleaner, oil type . . . . . . . . . . . . . . . . . . . . . . . . . . .1–4 .

Air Housing, installation . . . . . . . . . . . . . . . . . . . . . .5–18 .

Bolts and Studs, tightening . . . . . . . . . . . . . . . . . . . . 6–1 .

Brake, adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29 ..

Brake, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28 ..

Brake, disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .3–28 .

Camshaft (Petter), installation . . . . . . . . . . . . . . . . . . 7–7 .

Camshaft (Wisconsin), installation . . . . . . . . . . . . . .5–14 Camshaft (Petter), removal . . . . . . . . . . . . . . . . . . . . 7–3 .

Camshaft (Wisconsin), removal . . . . . . . . . . . . . . . .5–12 Camshaft Gear (WIsconsin), installation . . . . . . . . . 5–17 Carburetor, adjustment . . . . . . . . . . . . . . . . . . . . . . . .5–2 .

Carburetor and Manifold, installation . . . . . . . . . . . .5–18 Carburetor and Manifold, removal . . . . . . . . . . . . . .5–12 Carburetor Reconditioning . . . . . . . . . . . . . . . . . . . . . 5–2 .

Cartridge Release, adjustment . . . . . . . . . . . . . . . . . 4–4 .

Cartridge Release, checking pressure setting . . . . . 4–4 Checks and Adjustment (Deutz) . . . . . . . . . . . . . . . . .6–1 Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 ..

Clutch Needle Bearings, installing . . . . . . . . . . . . . . .3–9 Compression, check (Deutz) . . . . . . . . . . . . . . . . . . . 6–2 .

Compression, return to normal (Deutz) . . . . . . . . . . . 5–1 Connecting Rod (Petter), assembly . . . . . . . . . . . . . .7–8 Connecting Rod (Petter), removal . . . . . . . . . . . . . . .7–2 Connecting Rod Bearing (Deutz) . . . . . . . . . . . . . . .6–24 Control Valve Seal, disassembly . . . . . . . . . . . . . . . .4–10 Control Valve Seal, installation . . . . . . . . . . . . . . . . . 4–8 .

Cooling Air blower . . . . . . . . . . . . . . . . . . . . . . . . . . 6–29 ..

Cooling System, engine . . . . . . . . . . . . . . . . . . . . . . .1–8 .

Crankcase Air Vent (Deutz) . . . . . . . . . . . . . . . . . . . . 1–7 .

Crankcase Air Vent (Wisconsin) . . . . . . . . . . . . . . . . .1–7 Crankcase (Deutz), check . . . . . . . . . . . . . . . . . . . . 6–17 .

Crankshaft and Bearing (Deutz) . . . . . . . . . . . . . . . .6–19 Crankshaft (Deutz), check . . . . . . . . . . . . . . . . . . . . 6–17 .

Crankshaft (Deutz), reconditioning . . . . . . . . . . . . . .6–17 Crankshaft (Petter), removal . . . . . . . . . . . . . . . . . . . 7–2 .

Crankshaft (Wisconsin), installation . . . . . . . . . . . . .5–15 Crankshaft (Wisconsin), removal . . . . . . . . . . . . . . .5–14 Cylinder (Deutz), check . . . . . . . . . . . . . . . . . . . . . .6–25 .

Cylinder and Piston (Petter), installation . . . . . . . . . . 7–8 Cylinder Blocks (Wisconsin), installation . . . . . . . . . 5–15 Cylinder Blocks (Wisconsin), removal . . . . . . . . . . .5–14 Cylinder Head (Deutz), repair . . . . . . . . . . . . . . . . . 6–26 .

Cylinder Head (Petter), installation . . . . . . . . . . . . . . .7–9 Cylinder Head (Wisconsin), installation . . . . . . . . . . 5–17 Cylinder Head (Wisconsin), removal . . . . . . . . . . . .5–12 Cylinder Seals, installation . . . . . . . . . . . . . . . . . . . . 4–13 .

Decimal and Millimeter Equivalents . . . . . . . . . . . . . .8–9 .

Decompressor Adjustment . . . . . . . . . . . . . . . . . . . . 7–10 Distributor (Wisconsin), maintenance . . . . . . . . . . . .1–10 Drive Belt (Split Shaft), installation . . . . . . . . . . . . . . .3–9 Drive Chain, adjustment . . . . . . . . . . . . . . . . . . . . . .3–26 .

Driven Sheave Alignment . . . . . . . . . . . . . . . . . . . . .3–14 .

Driven Sheave, disassembly . . . . . . . . . . . . . . . . . . 3–13 .

Driven Sheave, installation . . . . . . . . . . . . . . . . . . . . 3–12 .

Driven Sheave, removal . . . . . . . . . . . . . . . . . . . . . .3–11 .

205 of 216 Revised Dec. 78

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SUBJECT

PAGE

Driven Sheave (Straight Jackshaft), assembly . . . . 3–14 Driven Sheave (Straight Jackshaft), disassembly . 3–14 Driven Sheave (Tapered Jackshaft) . . . . . . . . . . . . .3–13 Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11 ..

Engine (Deutz), assembly . . . . . . . . . . . . . . . . . . . . .6–6 .

Engine (Deutz), general data . . . . . . . . . . . . . . . . . . 6–31 . .

Engine (Deutz), reconditioning . . . . . . . . . . . . . . . . . 6–4 Engine (Petter), disassembly . . . . . . . . . . . . . . . . . . . 7–1 . .

Engine (Petter), timing . . . . . . . . . . . . . . . . . . . . . . .7–10 Engine (Wisconsin), assembly after reconditioning 5–14 Engine (Wisconsin), reconditioning . . . . . . . . . . . . .5–11 .

Engine (Wisconsin), removal . . . . . . . . . . . . . . . . . . 5–11 Engine (Wisconsin), return to service . . . . . . . . . . . .5–2 Engine (Wisconsin), storage . . . . . . . . . . . . . . . . . . . 5–2 . .

Engine Governor (Deutz), repair . . . . . . . . . . . . . . . 6–20 Flywheel (Wisconsin), installation . . . . . . . . . . . . . . 5–18 . .

Flywheel (Wisconsin), removal . . . . . . . . . . . . . . . . 5–11 Frame Support Variable Speed, removal . . . . . . . . .3–18 Front Cover (Deutz), check . . . . . . . . . . . . . . . . . . .6–20 .

Fuel Adjustment (Petter) . . . . . . . . . . . . . . . . . . . . . .1–8 .

Fuel Bowl (Wisconsin), disassemble . . . . . . . . . . . . .5–3 Fuel Bowl and Intake Assembly (Wisconsin), assemble . . . . . . . . . 5–3 Fuel Bowl and Throttle Body (Wisconsin), assemble 5–4 Fuel Filter (Petter), assembly . . . . . . . . . . . . . . . . . 7–10 .

Fuel Filter Lock–Off (Wisconsin), disassemble . . . . 5–10 Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–7 ..

Fuel Injection (Deutz), adjustment . . . . . . . . . . . . . . .6–3 Fuel Injection Nozzle (Deutz), removal–installation 6–30 Fuel Injection Pump (Deutz), check . . . . . . . . . . . . . .6–2 Fuel Pump (Petter), installation . . . . . . . . . . . . . . . . 7–10 .

Fuel System (Deutz), check . . . . . . . . . . . . . . . . . . . 6–2 .

Dealer Copy -- Not for Resale

SUBJECT

Gear Cover (Wisconsin), installation . . . . . . . . . . . .5–17 Gear Cover (Wisconsin), removal . . . . . . . . . . . . . . 5–12 .

Governor (Deutz), check and repair . . . . . . . . . . . . .6–23 Governor (Petter), removal . . . . . . . . . . . . . . . . . . . .7–4 .

Governor (Wisconsin), adjustment . . . . . . . . . . . . . . .5–1 .

Hydraulic Circuit, operation . . . . . . . . . . . . . . . . . . . .4–1 Hydraulic Cylinder, assembly . . . . . . . . . . . . . . . . . . 4–13 .

Hydraulic cylinder, disassembly . . . . . . . . . . . . . . . 4–13 . .

Hydraulic Fluid Filter, change . . . . . . . . . . . . . . . . . . 1–3 Hydraulic Oil, changing and adding . . . . . . . . . . . . . .1–2 Hydraulic Pump (500 electric), alignment . . . . . . . . 4–14 Hydraulic Pump (600 Wisconsin), alignment . . . . . 4–15 Hydraulic Pump (Cessna), assembly . . . . . . . . . . . .4–12 Hydraulic Pump (Webster), assembly . . . . . . . . . . .4–11 Hydraulic Pump, checking condition . . . . . . . . . . . . . .4–3 Hydraulic Pump (Cessna), disassembly . . . . . . . . .4–12 Hydraulic Pump Service (Webster) . . . . . . . . . . . . . .4–10 Hydraulic System (600 electric, 600 Peter) . . . . . . . . 4–2 Hydraulic System (600 & 610 Diesel w/Deutz Engine) . . . . . . . . . . . . .4–1 Hydraulic System (600 & 610 Gasoline & LP Gas) . 4–1 Hydraulic System, check pressure adjustment . . . . . 4–6 Hydraulic System, checking condition of . . . . . . . . . .4–2 Hydraulic Tanks, removing water . . . . . . . . . . . . . . . 1–2 .

Idler Gear and Shaft (Wisconsin), installation . . . . . 5–17 Idler Gear and Shaft (Wisconsin), removal . . . . . . . 5–12 Ignition Timing (Wisconsin) . . . . . . . . . . . . . . . . . . . .1–9 .

Injector, installation . . . . . . . . . . . . . . . . . . . . . . . . . 7–11 ..

600, 600D, 610, 611 Loader Service Manual

ALPHABETICAL INDEX PAGE

Jackshaft Bearing, installation . . . . . . . . . . . . . . . . . 3–15 .

Lower Jackshaft, installation . . . . . . . . . . . . . . . . . . 3–24 .

Lower Jackshaft, removal . . . . . . . . . . . . . . . . . . . . 3–23 .

Lower Jackshaft Sprocket, repair . . . . . . . . . . . . . . .3–24 LP Carburetor (Wisconsin), assembling . . . . . . . . . . 5–6 LP Carburetor (Wisconsin), cleaning & inspection . . 5–6 LP Carburetor (Wisconsin), disassembly . . . . . . . . . . 5–5 LP Carburetor (Wisconsin), reconditioning . . . . . . . . 5–5 LP Carburetor (Wisconsin), removal . . . . . . . . . . . . .5–5 LP Carburetor (Wisconsin), service . . . . . . . . . . . . . .5–5 LP Fuel Filter Lock–Off (Wisconsin) . . . . . . . . . . . . .5–10 Lubrication, loader . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 ..

Main Bearing (Deutz), check–installation . . . . . . . . 6–18 Oil, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–5 ..

Oil Filter (Deutz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 ..

Oil Filter (Petter) . . . . . . . . . . . . . . . . . . . 1–6, .

7–4, 7–10 Oil Filter (Wisconsin) . . . . . . . . . . . . . . . . . . . . . . . . . .1–6 .

Oil Pan (Wisconsin), installation . . . . . . . . . . . . . . . .5–16 Oil Pan (Wisconsin), removal . . . . . . . . . . . . . . . . . 5–12 .

Oil Pump (Deutz), checking . . . . . . . . . . . . . . . . . . . 6–20 .

Oil Pump (Petter), lubricating . . . . . . . . . . . . . . . . . . 7–6 .

Oil Pump (Petter), removal . . . . . . . . . . . . . . . . . . . . 7–4 .

Oil Pump (Wisconsin), installation . . . . . . . . . . . . . .5–16 Oil Pump (Wisconsin), removal . . . . . . . . . . . . . . . . 5–12 .

SUBJECT

PAGE

Valve Rocker (Petter), adjustment . . . . . . . . . . . . . .7–10 Valve Rocker Gear (Petter), installation . . . . . . . . . .7–10 Valve Spool Seals, installing in variable speed control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–9 ..

Valve and Seat Inserts, installation . . . . . . . . . . . . . .5–15 Valves and Seat Inserts (Wisconsin), removal . . . . 5–13 Valves Tappets (Wisconsin), removal . . . . . . . . . . . .5–14 Vaporizer (Wisconsin), adjustment . . . . . . . . . . . . . . .5–9 Vaporizer (Wisconsin), assemble . . . . . . . . . . . . . . . 5–8 .

Vaporizer (Wisconsin), disassembling . . . . . . . . . . . .5–8 Vaporizer and Primary Regulator (Wisconsin), service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8 ...

Variable Driven Sheave and Roto–Swivel Inside, removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16 ..

Variable Sheave with Roto–Swivel Outside, removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–18 ..

Variable Speed Control Valve, disassembly . . . . . . . 4–7 Variable Speed Control Valve Seal Replacement . . . 4–7 Variable Speed Valve Pressure, checking . . . . . . . . . 4–5 Variable Speed W/Roto–Swivel Inside, assembly . 3–17 Water Scrubber Muffler (600 Diesel) . . . . . . . . . . . . .1–8

Dealer Copy -- Not for Resale

SUBJECT

Piston (Petter), assembly . . . . . . . . . . . . . . . . . . . . . .7–9 .

Piston (Deutz), check and measuring . . . . . . . . . . .6–25 Piston and Connecting Rods (Wisconsin), installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–16 ..

Pistons and Connecting Rods (Wisconsin), removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–13 ..

Piston Pin Busing (Deutz check & replacement . . . 6–25 Piston Rings (Wisconsin), installation . . . . . . . . . . .5–15 Rocker Arm, repair . . . . . . . . . . . . . . . . . . . . . . . . . .6–29 .

Roto–Swivel, assembly . . . . . . . . . . . . . . . . . . . . . .3–17 .

Roto–Swivel, disassembly . . . . . . . . . . . . . . . . . . . . 3–17 .

Service, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 ..

Service, schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 ..

Spark Plug (Wisconsin) . . . . . . . . . . . . . . . . . . . . . .1–10 .

Specifications 600 (Gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8A–3 ..

610 (Gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8A–4 ..

600 (Deutz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8B–4 ..

611 (Deutz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8B–5 ..

611 (B of MA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8B–6 ..

600 (Petter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8C–4 ..

600E (Electric) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8D–1 ..

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12 ..

Throttle Body, assemble . . . . . . . . . . . . . . . . . . . . . . .5–4 .

Throttle Body, disassemble . . . . . . . . . . . . . . . . . . . . 5–2 .

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 ...

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10 ...

Torque Specification for Bolts . . . . . . . . . . . . . . . . . . 8–8 .

Torques, machine . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10 ..

Troubleshooting the Drive System . . . . . . . . . . . . . . .2–1 .

Troubleshooting the Engine . . . . . . . . . . . . . . . . . . . 2–11 Troubleshooting the Hydraulic System . . . . . . . . . . . .2–5

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600, 600D, 610, 611 Loader Service Manual

019 Bulletin Number

®

25 AUGUST 77

SERVICE BULLETIN

Date

AFFECTING: Product BOBCAT LOADER Model

610, 620, 630, 700, 720

Manual No. PROBLEM:

CAUSE: 1.

Fuel pump pressure is too high.

2.

Float level needs adjustment.

CORRECTION: 1.

Check fuel pump pressure by installing a ‘‘Tee’’ in the fuel line between fuel pump and carburetor and connecting a gauge to the tee. Run engine at full RPM. Correct pressure is 2–3 PSI. If pressure is too high, install new spring from fuel pump repair kit, part number 6516387.

NOTE: Too low pressure will cause vapor lock.

2.

Make adjustment of float level. The standard dimension as stated in the Service Manuals is specified as 1–5/32’ ’ (Page 79, 610 S/M; Page 7–5, 700 S/M). It is sometimes helpful to change the float level adjustment to 1–1/4’ ’. This is the recommendation for operation in areas of rough ground.

POLICY: Melroe will give compensation for parts and one hour labor.

No.(s) 207 of 216

Printed in U.S.A.

BULLETIN STATUS NON–CURRENT

Dealer Copy -- Not for Resale

Too much fuel to engine.

208 of 216

Dealer Copy -- Not for Resale

042 Bulletin Number

®

23 FEBRUARY 78

SERVICE BULLETIN

Date

AFFECTING: Product BOBCAT LOADER Model

600, 600D, 610, 611

Manual No. 6556276 SUBJECT: SERVICE MANUAL REVISION

No.(s) 209 of 216

Remove Cover Page

Put In New Cover Page

Page 1–1 Pages 1–9 & 1–10 Page 5–1

Page 1–1 Pages 1–9 thru 1–20 Page 5–1

Printed in U.S.A.

BULLETIN STATUS NON–CURRENT

Dealer Copy -- Not for Resale

This Service Bulletin has 15 printed pages, count them to be sure you have all of them.

210 of 216

Dealer Copy -- Not for Resale

600–002 ®

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT LOADER Model

610

Revision Number

5 FEBRUARY 80 Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6556276 (1–78) Insert This Sheet With The Above Listed Manual For Future Reference.

The following pages are a revision to the above Service Manual.

Take out existing pages and put in the new pages as listed below: TAKE OUT

PUT IN

1–1, 1–2 1–3, 1–4 1–5, 1–6

Revised 1–1, 1–2 Revised 1–1, 1–4 Revised 1–5, 1–6 Added 1–7a Revised 1–7, 1–8 Revised 3–1, 3–2 Added 3–2a Added 3–2b Revised 3–3, 3–4 3–5, 3–6 Revised 3–7, 3–8 Revised 4–1, 4–2 Revised 4–3, 4–4 Revised 4–15 Added 4–16 Revised 5–9, 5–10 Revised 5–17, 5–18 Revised 6–1, 6–2 Revised 8A–1, 8A–2 Revised 8A–3, 8A–4 Revised 8B–1, 8B–2 Revised 8B–3, 8B–4 Revised 8B–5, 8B–6 Revised 8C–1, 8C–2 Revised 8E–1, 8E–2

1–7, 1–8 3–1, 3–2 3–3, 3–4 3–5, 3–6 3–7, 3–8 4–1, 4–2 4–3, 4–4 4–15 5–9, 5–10 5–17, 5–18 6–1, 6–2 8A–1, 8A–2 8A–3, 8A–4 8B–1, 8B–2 8B–3, 8B–4 8B–5, 8B–6 8C–1, 8C–2 8E–1, 8E–2

211 of 216

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NOTICE

212 of 216

Dealer Copy -- Not for Resale

600–003 ®

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT LOADER Model

600, 610

Revision Number

22 APRIL 80 Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6556276 (1–78) Insert This Sheet With The Above Listed Manual For Future Reference.

The following pages are a revision to the above Service Manual.

Take out existing pages and put in the new pages as listed below: TAKE OUT

PUT IN

5–15, 5–16

Revised 5–15 Revised 5–16 Revised Mar. 8A–1 Revised Mar. 8A–2

Revised Feb. 8A–1 Revised Feb. 8A–2

213 of 216

Dealer Copy -- Not for Resale

NOTICE

214 of 216

Dealer Copy -- Not for Resale

ROUTE TO ATTENTION

SERVICE MANUAL REVISION

NOTICE

Insert This Sheet With The Below Listed Manual For Future Reference.

600-004 15 June 2012 Bobcat Loader 600, 600D, 610, 611 6556276 (6-87)

The following Sections are a revision to the above Service Manual.

COVER

215 of 216

X

SMR-1

Dealer Copy -- Not for Resale

Revision No: Date: Product: Model: Manual No:

PARTS MANAGER SERVICE MANAGER SALES MANAGER

216 of 216

SMR-2

Dealer Copy -- Not for Resale