Bobcat 630 631 632 Service Manual 6556454 (2–87) - PDF DOWNLOAD

6 3 0

6 3 3 1 INCLUDES H SERIES

Service Manual

6 3 2

6556454 (2–87)

Printed in U.S.A.

© Melroe Company 1987

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

B-10731a

B-12365

B-7469

Never service the Bobcat SkidSteer Loader without instructions.

Use the correct procedure to lift or lower operator cab.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-11799

B-15231

B-15280

Have good ventilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and gas 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 part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device.

Replace it if damaged.

Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged.

Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

WRONG

WRONG

B-6590

B-6580 B-16102

B-6589 B-16102

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

Never service or adjust loader with the engine running unless 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 latch door before operating the loader.

Lead-acid batteries produce 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 performed 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.

MSW01-0805

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

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

PREVENTIVE MAINTENANCE

HYDRAULIC SYSTEM

A general inspection of the following items should be made whenever the machine has had service or repair: 1. Check hydraulic fluid level, engine oil level and fuel supply.

HYDROSTATIC SYSTEM

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

3. Lubricate the machine.

DRIVE SYSTEM

4. Check battery condition and cables.

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

6. Check electrical charging system.

MAIN FRAME

7. Check indicator lamps.

8. Check tires for wear and pressure.

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

10. Inspect safety items for condition (Operator Guard, Seat Belt, Safety Treads, Lamps, etc.).

ELECTRICAL SYSTEM

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

12. Operate the loader, checking all functions.

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

ENGINE SERVICE

TECHNICAL DATA

CONTENTS ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1

–1––3–

ALPHABETICAL INDEX

630, 631, 632 Loader Service Manual

–1––2–

630, 631, 632 Loader Service Manual

PREVENTIVE MAINTENANCE Paragraph Number BOB–TACH AND PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . .

1–8 ENGINE MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–9 ENGINE SERVICE (GENERAL) . . . . . . . . . . . . . . . . . . . . . .

1–3 HYDRAULIC FLUID AND FILTER . . . . . . . . . . . . . . . . . . . .

1–4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–1 LOADER LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–7 SERVICE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–2 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–6 TRANSMISSION & DRIVE SYSTEM . . . . . . . . . . . . . . . . . .

1–5

–1––1–

Page Number 1–16 1–17 1–4 1–14 1–1 1–16 1–3 1–15 1–15

PREVENTIVE MAINTENANCE

630, 631, 632 Loader Service Manual

–1–0–

630, 631, 632 Loader Service Manual

1 PREVENTIVE MAINTENANCE Engine Serial Number

1–1 INTRODUCTION 1–1.1 Symbols

IMPORTANT This notice identifies procedures which must be followed to avoid damage to the machine.

B–02674R

Fig. 1–1 Loader Serial Number

I–2019–0284

B–02120

Fig. 1–2 Engine Serial Number (630)

WARNING Warnings on the machine and in the manuals are for your safety.

Failure to obey warnings can cause injury or death.

W–2044–1285 1–1.2 Serial Number Identification It is important to make correct reference to the serial number of the loader when making repairs or ordering parts. It is possible that the present machines do not use all the same parts as earlier machines: or it is possible that different procedures are used for service or repair.

1–1.3 Loader Serial Number

B–02249

The loader serial number plate location is on the inside of the lift upright, above the grill (Fig. 1–1). Explanation of serial number: XXXX

M

Fig. 1–3 Engine Serial Number (631)

XXXX Production Sequence (Series) Plant Location Model, Engine Version

Engine Serial Number

1–1.4 Engine Serial Number 630 Winsconsin: (Fig. 1–2) The engine serial number location is on the engine shroud on the left side of engine. Use all numbers when ordering parts for this engine.

631 Deutz: (Fig. 1–3) The engine serial number location is on the right side of the cylinder block. Use all numbers when ordering parts for this engine.

632 Ford: (Fig. 1–4) The engine serial number location is on the right side of the valve cover. Use all numbers when ordering parts for this engine.

B–02796

Fig. 1–4 –1–1–

Engine Serial Number (632)

630, 631, 632 Loader Service Manual

1–1.5 Pre–Delivery Inspection The purpose of the pre–delivery inspection is to make sure that the loader is in correct operating condition when it comes to the dealer and before delivery to the customer.

The pre–delivery inspection also lets the factory know when something is wrong with the loader so that the problem can be corrected and prevented in the future.

All items on the inspection form (Fig. 1–5) must be completed according to specification in this manual.

One copy of the completed form is to be mailed to: CLARK EQUIPMENT COMPANY MELROE DIVISION QUALITY CONTROL DEPT. GWINNER, NORTH DAKOTA 58040

Fig. 1–5 Pre–Delivery Inspection

The other copy is for the dealer.

1–1.6 30 Hour Inspection The 30–hour inspection must be completed soon after the first 30 hours of operation.

The purpose of the 30–hour inspection is: 1. For adjustment and inspection after first work period 2. To correct wrong maintenance and operation methods.

3. For demonstration of correct service procedures to customer.All items on the 30–hour inspection form (Fig. 1–6) must be completed by the dealer’s mechanic, according to specification in this manual.

Fig. 1–6 30 Hour Inspection

When the 30 hour inspection has been completed, the form must be signed by (1) the mechanic that completed the inspection, (2) the dealer, and (3) the owner or operator.

One copy of the completed form is to be mailed to: CLARK EQUIPMENT COMPANY MELROE DIVISION - SERVICE DEPARTMENT GWINNER, NORTH DAKOTA 58040 One copy is for the owner and one copy is for the dealer.

–1–2–

630, 631, 632 Loader Service Manual

1–2 SERVICE INTERVALS Maintenance work must be done regularly. Failure to do so will result in damage to the machine or its engine. The service schedule must be used as a guide to correct maintenance of the Bobcat loader. Use this schedule unless it is to shorten the intervals due to extremely hot, cold, dusty or corrosive operation conditions.

BOBCAT SERVICE SCHEDULE*

ITEM Engine Air Cleaner Engine Oil Engine Cooling System Engine Coolinf Inlet Tires All Pivot Points Indicators, etc.

Operator Guard Seat Belt Safety Decals Hydraulic Fluid Engine Oil & Filter Crankcase Breather Battery Control Pedals & Steering Bob–Tach Brakes Distributor Cam (Wisconsin) Spark Arrestor Muffler Chaincase Fluid Hydraulic Filter Engine Cylinder Head Bolts Engine Air Cleaner Crankcase Breather Valve Tappets Starting Motor Engine Fuel Filter Main Fuel Filter Engine Compression Chaincase Hydraulic System

HOURS 8–10 50 100 250 300 500 1000

630 631 632

SERVICE SCHEDULE SERVICE REQUIRED Clean dust cup. Inspect condition of system.

Check and add oil as necessary.

Check coolant lever. Add coolant when low. Remove any debris from radiator grill area.

Check rear door grill and blower inlets for restriction of air flow. Clean cylinder cooling fins and blower housing, when necessary.

Inspect for damage and check air pressure in tires.

Add lubricant to all fittings (12).

Check for correct operation of all inficatos, switches, lights.

Check condition of guard and bolts.

Check condition of straps and buckle and make replacement if there is a defect.

Be sure all decals are in place and can be read. Make replacement as necessary.

Check level and add recommended fluid if necessary.

Make replacement of oil and filter.

Clean breather cap every oil change.

Check water level. Add water if necessary.

Check operation. Make repairs and adjustments as necessary.

Inspect locking levers and wedges for condition and operation.

Check operation. Make adjustment as necessary.

Put 3 – 5 frops of oil in spring cap oil cup.

Remove plug. Run engine to remove carbon.

Check level. Add fluid if necessary.

Make replace of filter element.

Tighten to correct torque after first 100 hours. Also make adjustment to valves if necessary.

Inspect system for leaks. Replace element, if necessary.

Remove and clean breather assembly.

Check clearance. Make adjustment when required.

Remove, clean and serice as required.

Replace element or clean as necessary.

Make replacement of element (Vent air from system after chainging element.)

The minimum compression reading must be at least 75% of maximum compression reading.

Make replacement of fluid.

Make replacement of fluid and filter. Clean cap and vent.

–1–3–

630, 631, 632 Loader Service Manual

1–3 ENGINE SERVICE The rear door must be opened to service the engine. Pull the door latch to the left to open the door (Fig. 1–7).

1.11–1.17

1/2’’

WARNING

5.83 5.89

Door must be closed when operating the loader.

W–2313–0498

In some conditions the rear door can be lifted upward and the lower hinge can come out of the hole in the upright.

A door stop can be installed to prevent the door hinge from coming out of the hole.

B–02196

Fig. 1–7 Releasing Rear Door

A–02506

Fig. 1–8 Hole Location

To install the door stop: 1. Drill a 1/2’’ hole in the upright above the lower hinge (Fig. 1–8).

2. Install the door stop on the inner side of upright (Fig. 1–9).

Door Stop

3. Install the bolt and nut and tighten to 40–50 ft.–lbs. (54,2–67,8 Nm) torque.

Bolt

NOTE: On the 630; S/N 13205 & Up, 631; S/N 13225 & Up have a rear door stop installed. Push down on the door stop to hold rear door open while servicing the engine. Be sure to disengage the door stop before closing the rear door (Fig. 1–10).

B–02914

Fig. 1–9 Door Stop Installation

Release Lock

Door Stop

Rear Door Hinge

B–03006

Fig. 1–10 Door Stop –1–4–

630, 631, 632 Loader Service Manual

1–3.1 Engine Oil and Filter (Fig. 1–11 thru Fig. 1–14) Oil Specification: 630 and 632: Use a good quality oil which has API Service Classification SE.

Oil Fill Cap

631: Use a good quality oil which has API Service Classification CD. Use oil of correct SAE viscosity for temperature conditions at the time of starting (See Page 1–6); not for the highest temperature expected during the working day.

Engine Oil Filter

Drain Plug

C–02256

Fig. 1–11 Engine Servicing (630)

Oil Fill Cap

Oil Fill Cap

Oil Drain Cap Fig. 1–12

Dipstick

C–02299

Engine Servicing (631)

–1–5–

630, 631, 632 Loader Service Manual

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

SAE 10W–30

SAE 15W–40

SAE 5W–30 SAE 30W

Minimum

SAE 20W–20

SAE 10W

⎧°–30 –20

–10

0

+10

+20 +30

+40 +50 +60

+70

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

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

Maximum Fig. 1–13

B–02663

Checking Crankcase Oil (632)

Checking Oil: Engine must be stopped to check oil level. Check oil level every 4 hours for the first 50 hours of operation. After the first 50 hours of operation, check oil level every day, (8–10 hours). Oil level must be kept between the ‘‘MIN’’ and ‘‘MAX’’ marks on the dipstick.

Adding Oil: Remove oil fill cap add enough oil of the correct specification and viscosity to make oil level near the ‘‘MAX’’ on the dipstick.

Oil Filter

Replacement Oil and Filter:

Crankcase Drain

1. Stop the engine.

2. Remove drain plug when engine is hot.

3. Remove the engine oil.

B–02658

4. Remove filter.

Fig. 1–14 Engine Oil Filter Location (632) 5. Install drain plug.

6. Clean area around filter base.

NOTE: There may be a failure of the oil filter bracket on the 630 Bobcat due to engine vibration. Install a new bracket (P/N 6558773) on the loader frame by drilling a hole in the loader frame (behind engine plate) and installing a 3/8’’ carriage head bolt and nut (Fig. 1–15).

7. Put clean oil on gasket of new filter and install new filter. Tighten filter by hand only.

8. Fill with 4 quarts (3,791.) of oil of the correct specification and viscosity.

C–02317

Fig. 1–15 –1–6–

Filter Location (630)

630, 631, 632 Loader Service Manual

1–3.2 Crankcase Breather 630 Wisconsin: the crankcase breather is a closed system and does not need service.

Breather Cap

632 Deutz: (Fig. 1–16) the crankcase breather is located on the right side of the cylinder block. Clean the breather assembly every 500 hours.

632 Ford: (Fig. 1–17) the crankcase breather is also the oil fill cap. Clean the breather cap in solvent every time you replace the engine oil.

1–3.3 Air Cleaner System

A–01601

Fig. 1–16 Crankcase Breather (631)

The air cleaner system must be kept clean and free from defects for good engine performance and long service life.Service air cleaner as follows: 1. Remove and clean dust cup every day (Fig. 1–18).

B–02677

Fig. 1–17 Crankcase Breather (632)

2. Do not remove element unless replacement is necessary.

NOTE: Be sure (1) gasket surfaces are clean before installing new element and (2) be sure gasket is in correct place.

Condition Indicator

3. Inspect complete air cleaner system and make replacement of any parts with defects. Be sure hose connections are tight.

4.

Gasket

Element Rubber Baffle

Dust Cup

Check running operation of air cleaner system as follows: a. Start engine and run at idle. b. Close air inlet on air cleaner.

The engine speed must become slower then stop (630, 632 only).

Check the condition indicator for the red ring (631); if the red ring appears, the system is good.

Clamp C–01024R

Fig. 1–18

Air Cleaner Assembly

c. If the engine does not stop, the system has a leak. Inspect, and make repairs as necessary.

Hose Clamp

NOTE: Use special care when installing and tightening the hose clamp on the carburetor on the 632 Bobcat engine. Because of the short clamp area on the air inlet of the carburetor the clamp and the hose must be pushed toward the carburetor when the clamp is being tightened (Fig. 1–19).

B–02409

Fig. 1–19

Carburetor Clamp

–1–7–

630, 631, 632 Loader Service Manual

1–3.4 Fuel System (630, 632) Use only ‘‘regular’’ gasoline with an octane rating of 90–94. DO NOT USE UNLEADED GASOLINE. 1. Engine must be stopped, ignition off, and the engine cool before putting fuel in tank.

Fuel Cap

2. Remove fuel cap (Fig. 1–20) and fill tank with clean fuel using an approved safety container.

3. Put fuel in the tank ONLY when the machine is in a large open area (outside or a large building).

WARNING

Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire.

W–2063–0887

B–02654

Fig. 1–20

Fuel Fill Location

4. Use only clean fuel.

5. Install fuel cap after filling. Be sure fuel cap is tight.

Fuel Tank

Fuel Filter A fuel filter is located on the right side of the loader near the fuel tank outlet (Fig. 1 - 15).

NOTE: On some model loaders may not have the manual ‘‘shut–off’’. Install the parts as shown in figure 1–21 (See Parts catalog for the Parts).

Adapter (Diesel Model)

The fuel filter must be replaced every 1000 hours.

To check or make replacement of fuel filter.

1. Turn fuel valve off (Fig. 1–21).

2. Loosen hose clamp and remove hose from outlet end of fuel filter.

3. Connect a short piece of hose to the outlet end of fuel filter and turn fuel valve on.

–1–8–

Fuel Fuel Filter ‘‘Shut–Off’’ (Gasoline Valve Model) B–02191

Fig. 1–21 Fuel Filter and Valve

630, 631, 632 Loader Service Manual

4. If fuel hose goes through the filter, it does not need replacement. If fuel does not go through filter, make replacement.

5. When installing new fuel filter, loosen both hose clamps to remove filter.

6. Install fuel filter with arrow towards carburetor (Fig. 1–21) and be sure fittings are tight.

1–3.4a Fuel System (631) See Section 7 for 631 fuel system maintenance.

Fuel Pump 630: The fuel pump is located on top of the cylinder block and under the intake manifold. Repair parts are not available for the fuel pump. If the fuel pump does not operate correctly, replacement must be made.

NOTE: Too much fuel to the engine can be caused by the pump pressure being too high. Check fuel pump pressure by installing a ‘‘Tee’’ in the fuel line between fuel pump and carburetor and connecting a gauge. Run engine at full RPM. Correct pressure is 2–3 PSI (13,79–20,68 kPa). If pressure is too high, install new spring (P/N 6516387). Also, too a low pressure will cause vapor lock.

632: The fuel pump is located on the left side of the engine above the starter.

Repair parts are not available for the fuel pump. If the fuel pump does not operate correctly, replace the pump.

Carburetor 630: The carburetor is located at the center of the engine on the intake manifold.

632: The carburetor is located on the left side of the engine, above and behind the fuel pump. Repair kits are available for the carburetor.

630: Carburetor 1–22).

Adjustment

Throttle Stop Screw

(Fig.

Adjust the idle screw for the best low speed operation.

Idle Adjustment Needle

The engine must idle at 1125 to 1150 RPM. Repair kits are available for this carburetor.

C–02319R

Fig. 1–22 Carburetor Adjustment (630) –1–9–

630, 631, 632 Loader Service Manual

632: Carburetor Adjustment (Fig. 1–23) The only adjustments to the carburetor are; (1) idle adjusting needle and (2) throttle idle adjustment.

Idle Adjusting Needle 1. Turn needle all the way in. DO NOT use force, it will cause damage to the needle.

2. Turn needle out (counterclockwise) about 1–1/2 turns, then start engine.

Throttle Idle Adjustment

3. If engine does not run smoothly, turn needle out until it does.

Throttle Idle Adjustment

B–02409

Fig. 1–23

Carburetor Adjustment (632)

1. Start the engine.

2. Hold governor speed change lever against the stop.

3. Make adjustment to throttle idle screw until engine runs 800 RPM. Cap

1–3.4b Fuel Shut–Off The 630 and 632 Bobcat are equipped with a fuel–shut (automatic). The fuel shut–off solenoid is activated when the ignition switch is turned ‘‘off’’ and shuts off the fuel to the carburetor.

Be sure to check the wires to the fuel shut–off solenoid for opens when the engine stops or will not start.

NOTE: On the 630; S/N 12,999 & Below and 632; S/N 12,046 & Below there is a kit available to install the fuel line shut–off on these loaders (See the Parts Catalog for Part Number).

1–3.5 Engine Cooling System 630 and 631: These engines are cooled with air. Be sure cooling fins on cylinder heads are kept clean.

632: Check coolant level at the coolant recovery tank (Fig. 1–24). The tank must be 1/3 full when cold. Also, when engine is cold, check to see that radiator is full.

B–02672R

Fig. 1–24

Coolant Recover Tank

1/2’’ (13 mm)

C–02299

Fig. 1–25 Belt Tension Adjustment (631) –1–10–

630, 631, 632 Loader Service Manual

1/2’’ Movement

WARNING Do not remove radiator cap when the engine is hot. You can be seriously burned.

1/4’’ Movement

W–2070–1285

Removing Coolant From System (632) 1. Disconnect wire from temperature switch, located on the right side of the engine block.

2. Remove switch.

temperature

sender

B–02661

Fig. 1–26

Belt Tension Adjustment (632)

3. After all coolant has come out, install switch and connect wire to switch.

1–3.6 Engine Electrical System (630, 631 & 632) The Bobcat has a 12 volt, negative ground, alternator charging system.

General service of the electrical system is as follows: 1. The factory battery is maintenance free. Batteries that are not maintenance free must have electrolyte checked every 50 hours.

2. Check battery cables to see that both are clean and tight. Remove corrosion with soda and water solution. Put grease on cable ends to prevent further corrosion.

3. a. 630: The 630 Bobcat has a flywheel type alternator. Check wires for damage condition. b. 631,632: Check alternator belt tension. Make adjustment for belt movement with 5 lbs. (2,27 kg) force (Fig. 1–25 & Fig. 1–26) as shown.

4. The 630 series Bobcats have two fuses located in the instrument panel (Fig. 1–27).

If any fuse is bad, it is caused by an overload in the electrical system. Check for a broken wire or broken insulation.

–1–11–

630, 631, 632 Loader Service Manual

Front Lights

Fuse Transmission Warning Light

Hourmeter Rear Light Voltmeter

Light Switch

Engine Warning Light

Kwy Switch

E–01299

Fig. 1–27

ROPS Electrical System

–1–12–

630, 631, 632 Loader Service Manual

1–3.7 Using An Extra Battery If it is necessary to use an extra battery to start the engine, be careful. This is a two person operation. There must be one person in the operator’s seat and one person to connect and disconnect the battery cables.

WARNING

You must wear goggles when you work near batteries. Do not let acid make contact with your body or clothing.

W–2312–0498

1. The ignition must be in the OFF position.

2. The battery to be used must be of the same voltage.

3. Battery terminals have identification marks. The positive terminal is marked (+) and the negative terminal is marked (–).

4. The negative terminal (–) of the battery must be connected to the engine or loader.

WARNING

You must wear goggles when you work near batteries. Do not let acid make contact with your body or clothing.

W–2312–0498

5. Connect the end of the first cable to the positive terminal (+) of the extra battery. Connect the other end of the same cable to the positive terminal (+) of the loader battery.

6. Connect the end of the second cable to the negative terminal (–) of the extra battery. Connect the other end of the second cable to the engine. DO NOT connect directly to the negative terminal (–) of the loader battery. Connecting cable directly to the negative terminal (–) of the loader battery can cause spark and destroy the battery and cause personal injury.

7. Keep the cables away from fans and belts.

NOTE: The operator must be in operator’s seat and have seat belt fastened.

8. Start the engine.

9. After engine has started, first remove the cable connected to the engine or loader.

10. Then remove cable from the loader battery positive terminal (+).

Damage to the alternator can occur if:

• Engine is operated with battery cables disconnected.

IMPORTANT

• Battery cables are connected when •

using a fast charger or when welding on the loader. (Remove both cables from the battery.)

Extra battery cables (booster cables) are connected wrong.

I–2023–1285

–1–13–

630, 631, 632 Loader Service Manual

1–3.8 Installing New Battery

EARLY MODELS

To remove the battery, pull back and lift up on the holddown lever (Fig. 1–28). On later models remove nuts and clamp (Fig. 1–29).

NOTE: On the 630; S/N 11060 & Below and 632; S/N 11212 & Below the battery holddown may bend. Install a new holddown rod which has been heat treated, part number 6553338 (P/N has not changed).

1. Remove battery cables and mark for correct installation.

2. Clean new battery connectors and cable ends.

3. Put new battery in same position as old one.

4. Fasten battery in place with the holddown lever or clamp.

5. Be sure cable ends do not touch any metal. Tighten the cable ends.

B–02231

1–3.9 Ignition System (630 & 632)

Fig. 1–28

Battery Hold Down

The basic items of the ignition system are coil, distributor and spark plugs.

Every 200 hours, check condition of points and make replacement of spark plugs.

LATE MODELS

Making Adjustment of Spark Plug Gap Clamp

1. Remove wires from spark plugs.

2. Remove spark plugs.

3. Remove carbon deposits from spark point.

4. Set spark plug gap. See Section 8 for correct gap.

5. Install spark plugs and wires.

Making Adjustment of Point Gap 1. Turn engine until rubbing block is on high point of cam.

2. Put correct thickness feeler gauge (See Section 8–Technical Data) between contact points.

3. Loosen adjustment screw. Move breaker arm contact until correct gap is given. Tighten screws again.

B–02946

Fig. 1–29

Battery Hold Down

1–4 HYDRAULIC FLUID AND FILTER Fluid Check level of hydraulic fluid every 50 hours (Fig. 1–30).

1. Turn lower check valve counterclockwise.

2. If hydraulic fluid comes from valve, fluid level is satisfactory.

3. If fluid does not come from valve, turn lower valve clockwise until tight. Turn upper valve counterclockwise and fill reservoir (See below for oil specifications) until fluid comes from upper valve. DO NOT OVERFILL. Turn upper valve clockwise until tight.

Upper Check Valve

Use only SAE 10W–30 or 10W–40 oil which has an API classification of SE.

IMPORTANT

DO NOT USE AUTOMATIC TRANSMISSION FLUID IN THE HYDRAULIC/HYDROSTATIC SYSTEM. I–2154–1297

–1–14–

Lower Check Valve B–02673

Fig. 1–30 Checking Hydraulic Fluid 630, 631, 632 Loader Service Manual

Filter Make replacement of hydraulic filter every 100 hours.

1. Remove hydraulic filter (Fig. 1–31).

2. Thoroughly clean surface where filter gasket will make contact.

3. Put clean oil on gasket of new filter.

4. Install new filter and tighten hand tight.

Oil Filter

5. Start the engine and inspect for leaks.

B–02665

1–5 TRANSMISSION AND DRIVE SYSTEM

Fig. 1–31

Hydraulic Oil Filter

Drive Chains The drive chains need replacement only when one becomes broken. (See Section 4 for replacement of drive chains).

Brakes Check brakes for correct operation every 50 hours.

Make adjustment to brakes as follows: (Fig. 1–31) 1. Put brake pedal in open position.

Adjustment Nut

1/4’’ Spacer

2. Check pedal and linkage for freeplay.

3. There must be 1/4’’ (6,35) of freeplay between the spacer and the nut at the rear end of linkage (Fig. 1–32). See Section 4 for brake pad replacement and complete installation of brakes.

Fluid Check transmission fluid level every 100 hours.

C–02366

Fig. 1–32 Brake Linkage Adjustment

1. Put Bobcat on a level surface.

2. Remove check plug (Fig. 1–33) located at the front of the transmission housing.

3. If fluid does not come out of check hole, add fluid through hole until it comes out.

NOTE: Use only SAE 10W–30 or 10W–40 oil which meets an API classification of SE. 4. Install check plug.

Make replacement of transmission fluid every 1000 hours. Remove the hydraulic filter element. Remove the hose from the filter housing and let fluid flow into the container.

1–6 Tires Check tires regularly for wear, damage and correct pressure. (Correct pressure is 45–50 PSI (310–340 kPa).

Plug C–02037

Fig. 1–33 –1–15–

Chaincase Check/Fill Plug

630, 631, 632 Loader Service Manual

Tire Rotation Tire rotation is necessary to be sure of even wear. Make tire rotation from front to rear, rear to front as shown in figure 1–34.

When new tires are installed, install two new tires at the same time and put both on the same side of Bobcat.

IMPORTANT DO NOT put fluid (ballast) in the tires on this loader.

I–2153–1297 C–01965R

Fig. 1–34 Tire Rotation Check wheel bolts regularly and make sure all are tight. (See Section 8 for torque specifications).

1–7 LOADER LUBRICATION Regular lubrication of the loader is important for good performance. Make lubrication at intervals according to 1–2 ‘‘SERVICE INTERVALS’’ on Page 1–3.

Figure 1–35 shows the location of grease fittings on the 630 series Bobcat.

6557316

Use a good quality lithium based, multi–purpose grease.

Fig. 1–35

Lubrication Points

Also put lubricant on the seat rails (Fig. 1–36).

1–8 BOB–TACH AND PIVOT PINS The Bob–Tach must be checked regularly for condition and wear (See 1–2 ‘‘SERVICE INTERVALS’’ on Page 1–3).

When levers are in ‘‘locked’’ position, the wedges must go through the holes in the frame of the attachment.Make replacement of bent or broken wedges.

All pivot points (Lift Arm, Bob–Tach and Cylinders) use pins which are held in place by lockbolts (Fig. 1–37).

Grease

Check lockbolt nuts to be sure all are tight.

NOTE: Some Bob–Tach’s will not fit into the mounting frame of attachments (Example: Pallet Fork, Angle Broom, etc.). Grind away 1/4’’ (6,35 mm) of material from each side of the Bob–Tach (Fig. 1–38).

B–02135

Fig. 1–36 Seat Rail Lubrication

Remove Material Here

B–02246

Fig. 1–37

Pivot Pin Lockbolts

–1–16–

D–01380

Fig. 1–38 Bob–Tach 630, 631, 632 Loader Service Manual

1–9 THE ENGINE MUFFLER The muffler on the engine of the 630 loader (S/N 13575 & Below) can come loose, because there is a failure of the studs at the manifold. Replace the studs and nuts which fasten the muffler to the manifold (Fig. 1–39, Items 1 & 2). Tighten the nuts to 14–18 ft.–lbs. (19–24 Nm) torque. (See the Part Book or Microfiche for the correct part numbers.)

2 1

E–01179

Fig. 1–39

–1–17–

Engine Muffler Installation

630, 631, 632 Loader Service Manual

–1–18–

630, 631, 632 Loader Service Manual

HYDRAULIC SYSTEM Paragraph Number CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–4 HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–1 HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–6 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–5 HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . .

2–2 HYDRAULIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . .

2–3 QUICK COUPLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–7

–2–5–

Page Number 2–9 2–7 2–12 2–12 2–7 2–8 2–18

HYDRAULIC SYSTEM

630, 631, 632 Loader Service Manual

–2–6–

630, 631, 632 Loader Service Manual

2 HYDRAULIC SYSTEM 2–1 HYDRAULIC CIRCUIT (See Pages 2–1 Thru 2–6) Mark a Line on Nut Flats of Both Nuts

1. The hydraulic fluid moves from the reservoir to the port block and the system hydraulic pump and to the control valve.

2. When the control valves are activated the cylinders move to the end of their stroke, then the hydraulic relief valve in the control valve opens to protect the system.

3. Fluid from control valve goes through the bronze filter in the port block and to the hydrostatic pumps. See Section 3 HYDROSTATIC SYSTEM to follow the passage of fluid through the hydrostatic system.

Tighten to Correct Amount from Chart

4. The by–pass valve in the port block will open if the pressure is more than 133 PSI (917 kPa). The extra pressure can be caused by; cold fluid, dirty filter or extra flow of fluid. (Extra flow of fluid is caused by retracting lift or tilt cylinder).

2–2 HYDRAULIC SYSTEM INFORMATION A–01897

Keeping Bobcat Clean

Fig. 2–1 Tighten Flare Fittings

IMPORTANT

When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

I–2003–0888

2–2.1 37° Flare Connections Use the following procedure to tighten the flare fittings: 1. Tighten the nut until it makes contact with the seat.

2. Make a line across the ‘‘flats’’ of both the make and female parts of the connection (Fig. 2–1).

3. Use the chart below to find the correct tightness needed.

Wrench Size

Tube Size Outside Dia.

Thread Size

Rotate No. of Hex Flats

5/8’’

5/16’’

1/2’’ – 20

2–1/2

11/16’’

3/8’’

9/16’’ – 18

2

7/8’’

1/2’’

3/4’’ – 16

2

1’’

5/8’’

7/8’’ – 14

1–1/2 – 2

1–1/4’’

3/4’’

1–1/16’’ – 12

1

1–3/8’’

1’’

1–5/16’’ – 12

3/4 – 1

2’’

1–1/4’’

1–5/8’’ – 12

3/4 – 1

2–1/4’’

1–1/2’’

1–7/8’’ – 12

1/2 – 3/4

O–ring

A–01852

Fig. 2–2

Straight Thread Seal

2–2.2 Tubelines and Hoses Make replacement of tubelines that have damage. A bent tubeline will cause a restriction, and a restriction will cause an increase in heat and a decrease in hydraulic action. Make replacement of hoses when wear or damage is present.

Use correct clamps to hold tubelines and hoses in position.

2–2.3 Straight Thread O–ring Connections

O–ring

These connections seal by compression of the O–ring. To tighten O–ring fittings, use this method: 1. Loosen the nut and slide the washer and O–ring against the thread (Fig. 2–2). Put oil on the O–ring.

–2–7–

A–01852

Fig. 2–3 Seal In Place 630, 631, 632 Loader Service Manual

2. Tighten the fitting in place by hand. If the fitting is an elbow turn the elbow until it is in alignment with the tubelines or hose.

3. Hold the fitting with a wrench. Use another wrench to tighten the jam nut (Fig. 2–3). The O–ring must fit into the space as shown.

O–ring

4. If the fitting is not turned in correctly, the O–ring will have damage and the fitting will leak (Fig. 2–4).

2–3 HYDRAULIC TROUBLESHOOTING PROBLEM

CHART

CORRECTION

Slow hydraulic action or no hydraulic power on all circuits.

A

Check control linkage and fluid level. Check release pressure and pump output. Check for damage to tubelines.

Slow hydraulic action or no hydraulic on one circuit.

B

Check control linkage, cylinder condition. Check valve section for leakage. Check for damage to tubelines.

Cylinders move the controls in neutral position (See NOTE Below).

B

Check cylinder condition.

Check valve section for leakage. Check for tubeline leakage.

O–ring

A–01897

Fig. 2–4 Wrong Installation

NOTE: If spool is not free in bore, turn spool 1/2 turn in its bore or loosen control valve from frame and tighten bolts evenly.

CHART A SLOW HYDRAULIC OR NO HYDRAULIC POWER TO ALL CIRCUITS Check Fluid Level

If Full

Check Control Linkage Adjustment & Free Movement

Check Release Pressure (Sec. 2–5)

If Good

Check Output Of Vane Pump (Sec. 2–6)

If Good

If Low

If Not Correct

If Not Correct

If Not Correct

Add Fluid

Make Corrections As Needed

Remove, Clean & Inspect Relief Valve (Sec. 2–5.1)

Make Repairs As Needed (Sec. 2–7)

CHART B SLOW HYDRAULIC OR NO HYDRAULIC POWER TO ONE CIRCUIT ONLY, CYLINDERS MOVE WITH CONTROLS IN NEUTRAL POSITION. Check Control Linkage Adjustment & Free Movement

If Not Correct

Make Repair Or Adjustment As Needed

If Correct

Check Condition Of Cylinders (Sec. 2–8.1)

If Bad

Make Repairs Or Replacement As Needed (Sec. 2–9)

–2–8–

If Good

Remove, Clean & Inspect Control Valve (Sec. 2–10)

If Bad

Make Repair Or Replacement As Needed

630, 631, 632 Loader Service Manual

2–4 CONTROL VALVE

Relief Valve Tilt Orifice S/N 11463 & Above (.086’’)

Wear in the control valve or spools will cause the hydraulic cylinders to move when the controls are in neutral position.

Wear will also cause loss of hydraulic power.

Tilt Spring Assembly

NOTE: Loss of hydraulic power can also be caused by leakage inside the cylinders. (See HYDRAULIC CYLINDERS).

Lift Detent Assembly

O–ring

2–4.1 Removing Control Valve 1. Remove seat and transmission cover.

2. Disconnect control linkages, tubelines and hoses from control valve.

Load Check Valve

Auxiliary Detent Assembly Lift Orifice (.125’’)

D–01385R

Fig. 2–5 Control Valve Assembly

3. Remove two bolts which hold the control valve to the fender, and remove the control valve.

2–4.2 Disassembly and Inspection of Control Valve (Fig. 2–5) NOTE: Be sure to remember the location of each spool and return it to the same bore during assembly.

1. Push lift and auxiliary spools into detent position (Fig. 2–6).

2. Loosen screws in caps and remove caps and spools at the same time. (See 2–4.4 ‘‘Detent Spool Repair’’ for repair and service of lift and auxiliary spools.)

3. Remove wiper seals and O–rings from the bores.

4. Remove relief valve assembly (See 2–4.5 ‘‘Relief Valve’’ for service of relief valve.)

5. Remove load check valves (Fig. 2–7).

6. Inspect spools and bores for wear or scratches.

2–4.3 Assembling Control Valve NOTE: Use all new O–rings and put hydraulic fluid on parts during assembly.

1. Thoroughly clean O–ring grooves.

2. Install front (linkage end) O–rings and wiper seals.

3. Install tilt spool from the rear of control valve and push through so that end of spool is just beyond rear O–ring groove.

4. Install rear O–ring and push spool to the rear into the O–ring.

5. Install cap on tilt spool. Tighten bolt 6–8 ft.–lbs. (8–11 Nm) torque.

Detent Position Is All The Way In B–02821

D–01385R

Fig. 2–6 Control Valve –2–9–

Fig. 2–7 Load Check Valves 630, 631, 632 Loader Service Manual

6. Install lift and auxiliary spools the same way and put a screwdriver through the hole in tilt spool to keep other spools from moving when installing detent caps (Fig. 2–8).

Detent Caps

7. Install detent caps and install balls, springs and screws from detent device. Install bolts and tighten to 6–8 ft.–lbs. (8–11 Nm) torque.

2–4.4 Detent Spool Repair (Lift and Auxiliary Spools) (Fig. 2–9)

B–02830

Fig. 2–8 Installing Detent Caps

1. Put linkage end of spool in vice.

B–02824

Fig. 2–9 Detent Repair

2. Remove screws, spring and balls from detent cap.

3. Remove springs.

4. Remove detent device.

5. Assembly is reverse of disassembly.

6. Be sure to install new O–ring on lift spool (Fig. 2–5).

2–4.5 Relief Valve The relief valve is like a safety valve; it opens when pressure gets high, releasing the pressure and protecting the hydraulic system.

Check Release Pressure 1. Stop the engine.

WARNING

Put jackstands under the front axles and rear corners of the frame before running the engine for service.

Failure to use jackstands can allow the machine to fall or move and cause injury or death.

W–2017–0286

2. Activate all hydraulic controls to release hydraulic pressure in the system.

3. Connect a tester or pressure gauge to auxiliary lines as shown (Fig. 2–10).

Tester can also be connected to tilt cylinder hoses.

B–02797

Fig. 2–10 Checking Release Pressure

NOTE: The flow control on the tester must be fully open.

4. Start engine and pun at fast RPM. 5. Operate auxiliary pedal and check pressure with tester. Relief pressure must be 1950 PSI (13,445 kPa).

6. Turn the allen screw in to increase the pressure or turn it out to decrease the pressure (Fig. 2–11).

Relief Valve Removal and Replacement 1. Stop the engine.

2. Activate all hydraulic controls to release hydraulic pressure in the system.

3. Remove relief valve assembly from the control valve (Fig. 2–5).

4. Clean and inspect all parts for wear or damage.

5. Install relief valve and check release pressure again. If pressure is not correct after cleaning, make replacement with new relief valve assembly.

6. Install new relief valve and check release pressure again.

B–02825

Fig. 2–11 Adjusting Relief Valve –2–10–

630, 631, 632 Loader Service Manual

Check Output of the Hydraulic Pump This test will determine the acceptable flow of the hydraulic pump. A hydraulic tester is required that will measure flow, temperature and pressure.

NOTE: Make sure that all the air is removed from the system before beginning the test. Air in the system can give an inaccurate test.

1. Remove the hose between the outlet of the hydraulic pump and the inlet of the hydraulic control valve.

2. Connect the inlet of the tester to the outlet of the hydraulic pump.

3. Connect the outlet of the tester to the inlet of the hydraulic control valve.

NOTE: Make sure that the restrictor valve on the tester is fully open.

4. Start the engine and run at low RPM. Make sure that the tester is connected correctly. If no flow is indicated on the tester, the hoses are connected backwards.

5. Increase the engine RPM to full RPM*.

6. Warm the hydraulic fluid to 140°F (60°C) by turning the restrictor knob on the tester to about 1000 PSI (6895 kPA). Do not exceed system relief pressure.

7. Open the restrictor on the tester and record free flow (GPM) at full RPM. 8. Disconnect any attachment from the auxiliary quick couplers and operate the auxiliary control lever. Record the high pressure (PSI) and the flow (GPM) at full RPM. 9. The high pressure flow must be at least 80% of free flow. %=

HIGH PRESSURE FLOW (GPM) FREE FLOW (GPM)

x 100

10. A low percentage may indicate a failed hydraulic pump, or it may be caused by air in the system. Make sure that all the air is removed from the system. * Make reference to your Model loader, in the Technical Service Guide for the system relief pressure and full RPM specifications. The system relief pressure must be per specifications before test is run.

–2–11–

630, 631, 632 Loader Service Manual

2–5 HYDRAULIC PUMP 2–5.1 Checking Output of Pump 1. Operate Bobcat for a few minutes until the oil is warm, before checking put output.

From The Hydraulic Control Valve

From The Tester Outlet

2. Stop the engine.

Tester Inlet

WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.

W–2017–0286

3. Remove wheels assembly.

and

seat

4. Connect the hydraulic tester into the system as shown (Fig. 2–12).

Open the flow control valve on the tester all the way.

IMPORTANT Do not turn the flow control valve (on tester) all the way off.

If you do, there will not be a relief valve in the system.

From The Tester Inlet

I–2025–0284

B–02798

Fig. 2–12 Checking Pump Output 5. Start engine and run at fast RPM. Turn the flow control valve slowly. Rear the low on the gauge. The flow at 2000 PSI (13789 kPa) must be at least 80% of the GPM shown in Section 8 ‘‘Technical Data’’. If flow is less, make repair or replacement of hydraulic pump.

2–5.2 Hydraulic Pump Replacement (Fig. 2–13) 1. Remove port block and hose from hydraulic pump.

2. Loosen bolts and remove hydraulic pump from hydrostatic unit.

3. Install new hydraulic pump and tighten bolts to torque shown in Section 8 ‘‘Technical Data’’.

4. Connect hose and port block to hydraulic pump.

2–6 HYDRAULIC CYLINDERS Leakage inside the hydraulic cylinders can cause loss of hydraulic power.

Remove Two Bolts

2–6.1 Checking Lift Cylinders 1. Stop the engine and activate controls to release hydraulic pressure.

B–02799

Fig. 2–13 Hydraulic Pump Replacement –2–12–

630, 631, 632 Loader Service Manual

WARNING

Put jackstands under the front axles and rear corners of the frame before running the engine for service.

Failure to use jackstands can allow the machine to fall or move and cause injury or death.

W–2017–0286

5. Open the rear grill and disconnect the hoses from the tubelines as shown (Figs. 2–14, 2–15). These hoses connect to the base end of the cylinder.)

Put plugs in the tubelines.

6. Start the engine and push the top of the lift pedal.

7. If there is leakage of hydraulic fluid from the hoses, remove the cylinder(s) for repair.

Remove Hose From Base End Of Lift Cylinder

2–6.2 Checking Tilt Cylinder 1. Stop the engine and activate controls to release hydraulic pressure.

B–02795

Fig. 2–14 Checking Lift Cylinder

2. Disconnect the hose that goes to the top (base end) of the tilt cylinder (Fig. 2–16). Put plug in hose.

3. Start the engine and push the heel of the tilt pedal.

4. If there is leakage from the open fitting on the cylinder, remove the cylinder for repair.

2–6.3 Removing Hydraulic Cylinder Remove Hose From Base End Of Lift Cylinder

1. Stop the engine.

2. Activate the controls to release hydraulic pressure from the system.

3. Disconnect hoses from the cylinder.

4. Remove bolts and pins that hold cylinder in place.

B–02794

Fig. 2–15 Checking Lift Cylinder

Remove Hose From Base End Of Tilt Cylinder B–02790

Fig. 2–16 –2–13–

Checking Tilt Cylinder

630, 631, 632 Loader Service Manual

2–6.4 Hydraulic Cylinder Repair NOTE: The following repair procedure can be used for both the large and small diameter cylinders.

Disassembly 1. Put the base end of the cylinder in the vise (Fig. 2–17).

2. Remove cylinder.

the

oil

from

the

B–03663

Fig. 2–17 Removing The End Cap

B–03087

Fig. 2–18 Removing The End Cap

3. Remove the end cap with a spanner wrench (large cylinder Fig. 2–17) (small cylinder Fig. 2–18).

4. Remove the rod with the end cap and piston (Fig. 2–19).

5. Remove the cylinder housing from the vise.

6. Put the rod end in the vise and remove the nut (Fig. 2–20).

7. Remove the piston (Fig. 2–21).

B–03665

8. Remove the piston (Fig. 2–21).

Fig. 2–19 Removing End Cap & Piston

B–03670

Fig. 2–20 Removing The Nut

9. Remove the end cap (Fig. 2–23).

10. Remove O–ring and back–up washer from the end cap (Fig. 2–24).

B–03683

Fig. 2–21 Removing The Piston

B–03693

Fig. 2–22 Removing O–ring

B–03685

Fig. 2–23 Removing The End Cap –2–14–

B–03670

Fig. 2–24 Removing O–ring 630, 631, 632 Loader Service Manual

11. Remove the wiper seal from the end cap (Fig. 2–25).

12. Remove the oil seal (Fig. 2–26).

13. Remove the teflon seal from the piston (Fig. 2–27).

14. Remove the O–ring on the piston (Fig. 2–28).

15. Wash all parts in solvent. Dry with air only. Destroy old seals and O–rings.

B–03701

Fig. 2–25 Removing Wiper Seal

B–03674

Fig. 2–26 Removing Oil Seal

Assembly The following tools will be needed to assemble the cylinders: Small Diameter Cylinder Piston Seal Tool: P/N 4127906 Rod Seal Tool: P/N 6559012 Large Diameter Cylinder Piston Seal Tool: P/N 6562764 Rod Seal Tool: P/N 6559013 B–03689

16. Make inspection of parts for scratches, nicks, bent, etc., replace as needed.

Fig. 2–27 Removing Teflon Seal

B–03703

Fig. 2–28 Removing The O–ring

17. Install piston over the piston tool (Fig. 2–29).

18. Install O–ring on piston using the tool (Fig. 2–30).

19. Install the teflon seal over the tool and on the piston (Fig. 2–31).

NOTE: To prevent damage to the teflon seal so not turn it into piston groove.

20. Install the piston into the tapered end of the tool (Fig. 2–32) to set the teflon seal to piston size diameter. Let the piston set in the tool for 5 minutes so that the teflon seal will take a set.

B–03674

Fig. 2–29 Installing Piston On Tool

B–03677

Fig. 2–31

Installing Teflon Seal

–2–15–

B–03675

Fig. 2–30 Installing O–ring

B–03673

Fig. 2–32 Installing Piston Into Tool 630, 631, 632 Loader Service Manual

21. Install the oil seal or the rod seal tool (Fig. 2–33).

NOTE: The O–ring side of the oil seal goes toward the inside of the cylinder.

22. Install the oil seal in the end cap (Fig. 2–34).

23. Install the wiper seal with lip toward the outside of the end cap (Fig. 2–35).

24. Install the back–up washer (Fig. 2–36).

B–03672

Fig. 2–33 Install Oil Seal On Tool

B–03671

Fig. 2–34 Installing Oil Seal

25. Install the O–ring (Fig. 2–37).

26. Put oil on the wiper seal and oil seal and install the cap on the shaft (Fig. 2–38).

27. Install the O–ring on the shaft (small cylinder only) (Fig. 2–39).

28. Remove the piston from the tool and install on the shaft (Fig. 2–40).

B–03682

Fig. 2–35 Installing Wiper Seal

B–03679

Fig. 2–36 Installing Back–Up Washer

B–03681

Fig. 2–37 Installing O–ring

B–03685

Fig. 2–38 Installing End Cap

B–03693

Fig. 2–39 Installing O–ring –2–16–

B–03692

Fig. 2–40 Installing The Piston 630, 631, 632 Loader Service Manual

29. Install the nut and tighten to the correct torque (See Section 8 for Specifications).

30. Put oil on the seals, O–rings and end cap threads (large cylinder (Fig. 2–42) (small cylinder Fig. 2–43).

31. Install the assembly in the cylinder housing (Fig. 2–44).

32. Tighten the end cap with a spanner wrench (large cylinder Fig. 2–45) (small cylinder Fig. 2–46).

B–03670

Fig. 2–41 Tightening Nut

B–03675

Fig. 2–42 Putting Oil On Seals

B–03691

Fig. 2–43 Putting Oil On Seals

B–03665

Fig. 2–44 Installing Assembly

B–03663

Fig. 2–45 Tightening End Cap

–2–17–

B–04682

Fig. 2–46 Tightening End Cap

630, 631, 632 Loader Service Manual

2–6.5 Tilt Cylinder Spacer (3’’ Tilt Cylinder)

630,631,632ServiceManual#6556454–HydraulicSystemSection

The tilt cylinder may go ‘‘over–center’’ when the load (such as wet dirt) is removed (dumped) from the bucket. On the 630; S/N 11406 & Below, 631; S/N 11010 & Below and 632; S/N 11809 & Below loaders which have this problem, install a 1/8’’ (3,175 mm) thick spacer in the tilt cylinder between the piston and cylinder gland (head). See figure 2–47 for dimensions and installation.

NOTE: Installing a 1/8’’ (3,175 mm) spacer will shorten and reduce the angle of the bucket by 2–1/2 degrees when the bucket is tilted fully forward.

2–7 QUICK COUPLERS 2–7.1 Restriction in the Quick Couplers (Early Models Only) If there is not enough oil flow through the quick couplers there will be high back pressure, on the hydraulic system, and slow attachment operation.

The adapter on the male quick coupler has a ‘‘taper’’ end which can cause the restriction in the hydraulic oil flow and over–hearting. Remove the quick coupler (Fig. 2–48) and the adapter and cut away the ‘‘taper’’ about 3/16’’ (4,76 mm) (Fig. 2–49).

Do not cut the threads on the adapter.

2–3/4 in.

(69,85 mm)

1/8 in.

1–1/2 in.

(3,175 mm) (38,1 mm) Fig. 2–47 Installing Spacer In Tilt Cylinder

A–02644 C–02001

Quick Coupler Adapter

B–03522

Fig. 2–48 Removing The Quick Coupler

Remove 3/16’’ (4,76 mm) On This End Only

A–02704

Fig. 2–49 Quick Coupler Adapter –2–18–

630, 631, 632 Loader Service Manual

HYDROSTATIC SYSTEM Paragraph Number BY–PASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDROSTATIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDROSTATIC MOTORS (630 & 632 S/N 15320 & Below) . . . . . . . . . . . . . . . . . . . .

HYDROSTATIC MOTOR REPAIR (630 & 632 S/N 15320 & Below) . . . . . . . . . . . . . . . . . . . .

HYDROSTATIC MOTOR REPAIR (631 & 632 S/N 15321 & Above) . . . . . . . . . . . . . . . . . . . .

HYDROSTATIC PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . .

HYDROSTATIC TROUBLESHOOTING . . . . . . . . . . . . . . .

PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLENISHING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . .

–3–11–

Page Number

3–5 3–1

3–18 3–13

3–8

3–26

3–9

3–30

3–10 3–7 3–2 3–6 3–4 3–11 3–3

3–36 3–19 3–13 3–18 3–17 3–41 3–16

HYDROSTATIC SYSTEM

630, 631, 632 Loader Service Manual

–3–12–

630, 631, 632 Loader Service Manual

3 HYDROSTATIC SYSTEM 3–1 HYDROSTATIC CIRCUIT (See Pages 3–1 through 3–11) 1. Fluid from the hydraulic control valve goes to the bronze filter in the port block and then to the hydrostatic pumps. If the pressure to the filter is over mximum (as in cold weather starting), the by–pass valve in the port block opens and lets the fluid go the inlet of the hydraulic pump.

2. The flow of fluid to the hydrostatic pumps will keep the lines from the pumps to the motors full of fluid.

3. Leakage through the hydrostatic pumps and motors will cause fluid to go through the oil cooler and then to the inlet side of hydraulic pump.

3–2 HYDROSTATIC TROUBLESHOOTING If the fluid supply to the hydrostatic pumps is not enough (the bronze filter is full of dirt or one of the pumps has wear), the pressure switch at the port block will activate the ‘‘TRANS’’ light on the instrument panel. Also, if the fluid becomes hot, the temperature switch at the port block will activate the ‘‘TRANS’’ light.

NOTE: When light comes on, check which sender is activating light by removing pressure sender wire. If the light stays on, the temperature sender is activating the light and the fluid is overheating. If the light goes out there is not enough hydrostatic charge pressure.

PROBLEM

CHART

CORRECTION

No drive on one side in one direction.

None

Check for hydraulic leaks.

Check steering linkage, check replenishing valve (Sec. 3–4.1).

No drive, one side, both directions.

B

Check linkage. Check for pump or motor damage.

Machine does not move in a straight line.

C

Check dia. and size of tires steering linkage, see Chart B.

No drive on either side.

A

Check fluid level and steering linkage, make replacement of filter, inspect by–pass. Check vane pump.

–3–13–

630, 631, 632 Loader Service Manual

CHART A NO DRIVE ON EITHER SIDE

Check Fluid Level

If ‘‘Trans’’ Light Comes On

Turn Ignition Switch ‘‘ON’’

If Correct

If Light Does Not Come On

If Low

Make Repair Or Adjustment As Needed

Start Engine & Run At 1/2 Throttle

If Light Is On

Make Repairs Or Replacement As Needed (Sec. 2–9)

Make Repair Or Replacement As Needed

If Light Is On

Remove, Clean & Inspect By–Pass Valve (Sec. 3–5)

Check Vane Pump If Light Goes Out If Good

Make Repairs To Controls

If Light Is On

Hydrostatic Pump Has Defect. Remove, Clean & Inspect Pump And Motor (Sec. 3–6 & 3–8)

Check Pump Drive

CHART B NO DRIVE: 1 SIDE, BOTH DIRECTIONS

Check Steering Linkage

If Not Correct

Make Repairs As Needed (Sec. 3–10)

If Good

Turn Ignition Switch ‘‘On’’

If Light Is On

Start Engine & Run At 1/2 Throttle

If Light Is Not On

If Light Stays On

Repair Electrical System

Hydrostatic Pump Has A Defect

–3–14–

If Light Is Off But No Drive

Hydrostatic Motor Has Defect

NOTE: If Either The Pump or Motor Has Damage, Remove, Clean & Inspect Both Units.

630, 631, 632 Loader Service Manual

CHART C BOBCAT DOES NOT MOVE IN A STRAIGHT LINE

Check Size & Pressure Of Tires

If Correct

If Not Correct

Check Steering Linakge (Sec. 3–10)

Go To Chart B

If Correct

If Not Correct

Change Tire Or Pressure As Needed

Make Repairs As Needed

CHART D BOBCAT OVERHEATS

Check Fluid Level

If Correct

Check & Clean Oil Cleaner (Sec. 1–11)

If Clean

Check If Hydraulic Controls Are Being Held Out Of Neutral Position

If Low

If So

Add Fluid

Loader Is Not Being Operated Correctly

–3–15–

If Not

Check ‘‘Temp Sender’’

630, 631, 632 Loader Service Manual

3–3 STEERING LINKAGE ADJUSTMENT (Fig. 3–1 & 3–2)

TO THE FRONT OF THE BOBCAT

Adjust Bar Tight Against Both Lobes

WARNING Before the cab or the lift arms are raised for service, jackstands must be put under the rear corners of the frame.

Failure to use jackstands can allow the machine to tip backward causing injury or death.

W–2014–0895 1. Remove seat and steering shields.

NOTE: On the 630 (S/N 11512 & Below); 631 (S/N 1114 & Below); and 632 (S/N 12006 & Below), there are new pintle levers available if the old style breaks. To install the new pintle levers. (See BTI Bulletin #130.

Centering Spring Centering Bar Pintle Lever

Pintle Bar

630 (S/N 15300 & Below) 631 (S/N 12253 & Below) 632 (S/N 15450 & Below)

C–02375

Fig. 3–1 Steering Adjustment

Pintle Lever

Adjust Cam Tight Against Both Lobes

Cam

TO THE FRONT OF THE BOBCAT

2. Loosen four bolts that hold both pintle bars to strip.

3. Start engine and run at about 1/2 throttle.

4. Move the left steering lever until the wheels do not turn (neutral).

Adjust rear pintle bar so that the bar is tight against both lobes of pintle lever and the transmission is still in neutral.

Tighten bottom bolt first to 28 ft.–lbs. (38 Nm) torque, then tighten top bolt to 28 ft.–lbs. (38 Nm) torque.

Centering Bar Pintle Bar Fig. 3–2

630 (S/N 15301 & Above) 631 (S/N 12254 & Above) 632 (S/N 15451 & Above)

Centering Spring

C–02544

Steering Adjustment

5. Move the steering lever forward and backward and let the transmission return to neutral position. If the transmission does not return to neutral, make adjustment again. There must not be any space between the bar and the lobes.

6. Move the right steering lever until the wheels do not turn (neutral). Adjust the front pintle bar so that the bar is tight against both lobes of the pintle lever and the transmission is still in neutral. Check to see that there is no clearance between the bars and the lobes. Make adjustments as necessary. Tighten noth bolts to 28 ft.–lbs. (38 Nm) torque.

7. Move both steering levers forward and backward and let them return to neutral.

8. Tighten the bolts that hold the steering linkages to the pintle levers to 12 ft.–lbs. (16 Nm) torque while holding the bolts with a wrench install new lock nuts on each bolt and tighten to 23 ft.–lbs. (31 Nm) torque.

NOTE: The nuts at the front end of steering linkages go toward the center of machine.

9. Tighten two bolts at the front ends of steering linkages to 12 ft.–lbs. (16 Nm) torque.

–3–16–

630, 631, 632 Loader Service Manual

10. Install new locknuts on these bolts and tighten to 23 ft.–lbs.

(31 Nm) torque.

CHARGE FLUID

11. Install seat and seat plate.

12. Remove jackstand and lower lift arms.

3–4 REPLENISHING VALVE (Figs.

3–3 & 3–4)

FUNCTION 1 Valve Moves For Charge Fluid Replacement

The replenishing valves for forward motion are different from the replenishing valves for reverse motion.

The replenishing valves for forward motion also give release of very high pressure (Fig. 3–3, Function 3).

The functions of the replenishing valves are: 1. Give replacement fluid to low pressure side of closed hydrostatic circuit.

Replacement is needed because of normal inside leakage and the controlled flow to the cooler for cooling purpose (Fig. 3–3, Function 1 & Fig. 3–4, Function 1).

2. Keep high pressure fluid flow out of low pressure side of closed hydrostatic circuit (Fig. 3–3, Function 2 & Fig. 3–4, Function 2).

FUNCTION 2 Valve Stays On Seat To Hold High Pressure For Drive

FUNCTION 3 Fig. 3–3

B–02805

Replenishing Valve – Forward

3. Give release of very high pressure caused by very high load of the machine when moved in forward direction (Fig. 3–3, Function 3).

3–4.1 Checking Valves

Valve Release Very High Pressure To Protect System

CHARGE FLUID

Replenishing

If there is a loss of drive in one direction on one side, check as follows: 1. Remove both valves that control the direction (forward or reverse) of drive that was lost.

FUNCTION 1 Valve Moves For Charge Fluid Replacement

2. Make exchange of vales and check for loss of drive on the opposite side of machine. If there is loss of drive on the opposite side of machine, the valve that controls drive on that side needs replacement.

3. If exchange of valves does not change the side that has loss of drive, remove all four valves and clean the oil from valve seat area.

4. Put coloring fluid on the valves and let dry.

5. Use a small pliers to install valves into hole. Push the valves against the seat and turn it very little.

FUNCTION 2 Valve Stays On Seat To Hold High Pressure For Drive B–02804

Fig. 3–4

Replenishing Valves – Reverse

–3–17–

630, 631, 632 Loader Service Manual

6. Remove the valve and inspect the seat area of valve. If the seat area of valves does not show sign of full contact, the seat in pump assembly has defect and you must replace the valve block part of the hydrostatic pump.

3–5 BY–PASS VALVE (Fig. 3–5) 1. Disconnect, from port block, the hose between port block and reservoir (Item 1).

NOTE: S/N 630–13266 & Above; 631–11398 & Above; and 632–13463 & Above. The spring (P/N 6558498) in the by–pass valve has been replaced. The new spring part number is 6560082. The new spring will change the by–pass pressure from 140 PSI (965 kPa). This will help keep the by–pass vlave from opening during normal operating conditions, which can cause over–heating of the hydrostatic system.

1

2. Remove spring and valve from port block and inspect spring, valve and valve seat in port block for damage.

3. Assembly is reverse of disassembly.

B–02676

3–6 PUMP ASSEMBLY – REMOVAL AND INSTALLATION

Fig. 3–5

By–Pass Valve (630, 632 Only)

1. Stop engine and activate controls to release hydraulic pressure.

2. Remove ROPS (See 5–1 ROPS Removal).

3. Remove seat and seat plate.

4. Thoroughly clean dirt and other debris from pump and all around pump area.

Seal 5. Remove fluid from hydraulic system.

6. Remove port block from top of vane pump.

Spring

7. Remove hoses from vane pump and hydrostatic pumps.

IMPORTANT

When making repairs on hydraulic system, clean the work area before disassemble and keep all parts clean.

Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.

I–2056–0793

Bronze Element D–01434

Fig. 3–6 Vane Pump Drive Shaft 8. Remove four bolts that hold pump to transmission case and disconnect steering linkages.

9. Fasten chain hoist to hydrostatic pump assembly and lift the pump while sliding the pump forward.

10. Installation is reverse of removal.

3–6.1 Removing the Bronze Filter (Fig. 3–6) 1. Clean the port block area.

2. Remove the hose.

3. Pull the bronze filter element out with the O–ring seal from the port block.

4. If there are metal particals in the bronze filter, the complete port block must be removed and cleaned.

5. When installing the bronze filter, make sure that the O–ring seal is in the correct location.

6. Connect the hose.

–3–18–

630, 631, 632 Loader Service Manual

3–7 HYDROSTATIC PUMP ASSEMBLY – REPAIR

IMPORTANT

Shoes Turn This Direction On Wafer Plate

Keep all hydrostatic parts CLEAN! Dirt in the system will cause damage in a very short period of time.

I–2168–0498

The following procedure is for complete disassembly and assembly, but can also be used for partial disassembly and assembly.

NOTE: If O–rings, gaskets and shaft seals are removed, use new parts for assembly.

3–7.1 Hydrostatic Pump Disassembly

Wafer Plate Alignment Pin Fig. 3–7 Wafer Plate

B–02816

1. Put mark across all sections of hydrostatic pump assembly so that pump is reassembled in the correct way.

Gasket

2. Remove two bolts that hold vane pump to hydrostatic pumps.

Bearing

3. Remove O–ring, snap ring, collar with spline and vane pump drive shaft.

The tool listed will be needed to do the following procedure.

MEL1188 – Torx Socket 4. Remove six bolts that hold hydrostatic pump to manifold block.

5. Remove wafer plate and pin (Fig. 3–7).

Spacer

NOTE: Do not mix front and rear wafer plates. They are different.

6. Remove gasket, bearing and bearing spacer (Fig. 3–8).

IMPORTANT

B–02817

Fig. 3–8

Bearing Spacer & Gasket

Keep all the parts for one pump separate from parts for the other pump.

I–2164–0398

7. Remove rotating group from housing. Use both hands to keep pistons from falling out of cylinder block.

8. Put a mark on one piston and on one cylinder bore and remove pistons from cylinder block.

9. Remove four bolts that hold pintle covers on each side of housing and remove pintle covers.

IMPORTANT

Be sure not to damage shims under pintle covers. If shims are damaged, shims need repacement with shims of exact same thickness (unless new bearings are being installed. See 3–7.4, 3–7.5 Hydrostatic Pump Assembly).

I–2169–0498

10. Remove the O–rings and bearings spacers from each pintle.

11. Move yoke from side to side to loosen bearing races, remove races and remove bearings.

12. Turn the yoke at an angle and remove yoke and shaft together.

–3–19–

630, 631, 632 Loader Service Manual

13. Use a press to remove bearing from drive shaft and bearing race from housing. Use step 4 thru 12 for disassembly of the other pump unit.

This Dimension Must be Maintained on All Nine Shoes Within 0.001 Inch

Piston

IMPORTANT Keep parts for each pump separate. Some parts will fit both pumps but must not be used in the other pump because of specific wear patterns.

I–2165–0398

Shoe

Shoe Faces Sides On Swash Plate

Shoe Must Swivel Smoothly on Ball End Play Must Not Exceed 0.05 Inch A–01850

Fig. 3–9

Piston/Shoe Assembly

3–7.2 Hydrostatic Pump Inspection 1. Inspect shafts and collar for wear and/or damage to splines.

2. Inspect wafer plate for wear or damage. If grooves can be felt on the face with a fingernail, make replacement. Be sure new wafer plate is flat against manifold block.

3. Inspect bearings for wear and heat damage. Inspect bearing spacers for sharp edges.

4. Inspect rotating group. a. Check each piston in its cylinder. Piston must slide very easily in the cylinder bore. If piston does not move easily, clean pistons and bores and put fluid on both, then try again. b. Check end play of each piston assembly. End play must not be more than .005 inch. (0,127 mm) between piston and shoe (Fig. 3–9). c. Measure the thickness of each shoe. All shoes must be within .001 inch (0,025 mm) of each other. d. Inspect shoe plate for cracks in area of spherical washer. e. Check spherical washer for sharp edges, wear or scratches due to pin breakage. f. Inspect pins for wear or damage. All pins must be the same length and must not be bent.

WARNING If snap ring in cylinder block is removed before bolt is tightened against spring, the high tension spring can cause personal injury.

A–01868 A–01870

W–2317–0598

Fig. 3–10 Cylinder Block –3–20–

630, 631, 632 Loader Service Manual

g. Inspect spring, washer and snap ring in cylinder block. Disassemble as follows: Use a bolt and nut with washers to tighten against spring, remove snap ring and loosen bolt to relieve spring tension (Fig. 3–10).

If there are any defects in the rotating group, the complete unit must be replaced.

5. Inspect yoke for wear or damage.

3–7.3 Yoke, Pintle Bearing, etc. – Installation 1. Use a press to install bearing on drive shaft and bearing race into housing.

Push bearing and race until each are against shoulders on shaft and housing.

2. Put drive shaft through yoke and install both together into housing.

NOTE: Be sure long pintle shaft is on the correct side of housing.

3. Install pintle bearings and bearing races on each end of yoke.

4. Install bearing spacer on short pintle shaft.

5. Install new o–ring in groove.

NOTE: If new bearings and races were installed, go to step 10. If the same bearings and races are being used, follow with step 6 below.

6. Install the exact same shims that were removed (or new shims the same thickness) from pintle cover and install pintle cover on short pintle.

7. Install four pintle cover screws. If the screws have separate lock washers, tighten them to 115–125 in.–lbs. (12,9–14,1 Nm) torque. If the screws and lock washers are all one piece, tighten them to 170–190 in.–lbs. (19,2–21,5 Nm) torque.

8. Install same shims removed under pintle cover and install pintle cover/seal on long pintle shaft.

9. Install four pintle cover screws. If the screws have separate lock washers, tighten them to 115–125 in.–lbs. (12,9–14,1 Nm) torque. If the screws and lock washer are all one piece, tighten them to 170–190 in.–lbs. (19,2–21,5 Nm) torque.

10. If the new bearings and races were used, follow step a thru g below. a. Install one 0.010 inch (0,25 mm) shim under pintle cover and install pintle cover on short pintle. b. Install four pintle cover screws. If the screws have separate lock washers, tighten them to 115–125 in.–lbs. (12,9–14,1 Nm) torque. If the screws and lock washers are all one piece, tighten them to 170–190 in.–lbs. (19,2–21,5 Nm) torque. c. Set housing on side so that long pintle shaft is up. d. Install bearing spacer and turn yoke while pushing on spacer so that bearings and spacers are in correct position.

–3–21–

630, 631, 632 Loader Service Manual

e. Hold spacer against bearing race and measure the distance between spacer and face of housing. Measure in two places 180 apart (Fig. 3 - 11). Add the two dimensions and divide by 2 to get an average. Subtract the nominal preload of .008 (0,203 mm) (.007 to .009 (0,178 to 0,229) actual) from that average. The remainder after subtracting is the thickness of shim necessary to give correct preload on bearings.

EXAMPLE: (In Inches) .029 plus

.027

measured distance between spacer and housing face. measured distance at 180 from first measurement.

C–02272

Fig. 3–11 Checking Pre–Load Assembly

equals .056 .056 divided by 2 equals .028 average. .028 minus .008 (nominal preload) equals .020 .020 is the thickness of shim necessary

#2 Pump Housing

#1 Pump Housing

D–01392

Fig. 3–12 Hydrostatic Pump Assembly –3–22–

630, 631, 632 Loader Service Manual

NOTE: If thickness becomes more than .020 (0,508 mm) add another shim to short pintle side and do steps d thru e again. This is necessary to give correct compression of o–ring and prevent leakage at the seal.

Small End Of Bearing Toward Manifold Block

f. Install pintle cover/seal on long pintle shaft. g. Install four pintle cover screws. If the screws have separate lock washers, tighten them to 115–125 in.–lbs. (12,9–14,1 Nm) torque. If the screws and lock washers are all one piece, tighten them to 170–190 in.–lbs. (19,2–21,5 Nm) torque.

Chamfer Toward Pump

Use the same procedure to install yoke and bearings in other pump.

NOTE: The yoke must move with slight resistance, but must not move hard or with no resistance.

B–02817

Fig. 3–13 Bearing & Spacer

3–7.4 #2 Pump Assembly (Fig. 3–12) NOTE: If shaft bearings, shaft, valve block, housing or spacer were not installed new, use the same parts that were removed and go to step 2 below. If any new parts are used, follow with step 1 below.

1. Bearing Preload Adjustment a. Install thickest bearing spacer over shaft with the chamfer toward the shoulder on shaft (Fig. 3–13).

Shaft

b. Install bearing on shaft and against spacer. The small end of tapered bearing goes toward the manifold block (Fig. 3–13). c. Temporarily install vane pump shaft into intermediate shaft (Fig. 3–14). d. Install housing on manifold block without gasket and rotating group. Turn shaft while installing so that bearings are in correct position.

B–02818

Fig. 3–14

Vane Pump Drive Shaft

e. Install screws and tighten to 2 in.–lbs. (0,23 Nm) torque. Tighten strews evenly so that the gap is as even as possible. f. Use a feeler gauge to check the gap. A tapered feeler gauge is very good for this purpose. Measure gap at four different places; add the four dimensions together and divide by four to get an average gap dimension.

EXAMPLE (In Inches) minus plus plus equals

.150 measured thickness of thickest bearing spacer .027 average gap (from f. above) .003 ± .001 necessary preload .020 compressed thickness of gasket .146 ± .001 thickness of bearing spacer needed to give .001 to .003 bearing preload.

g. Remove six screws and remove housing from manifold block so that correct spacer gasket and internal parts can be installed.

Assemble Rotating Group 2. Install spring, two washers and snap ring in cylinder block (Fig. 3–10).

–3–23–

630, 631, 632 Loader Service Manual

3. Install pin retainer about 1/4 inch. (6,35 mm) below surface with opening away from large splines ( Fig. 3–15).

Three Pins

4. Push three pins in cylinder block until each hit spring washer in block.

5. Put spherical washer on top of three pins and install shoe plate and pistons.

Be sure all pistons slide freely in cylinder bores.

Installing Rotating Group Into Housing 6. Hold intermediate shaft horizontal and slide rotating group into housing.

Turn shaft until splines are in alignment.

Pin Retainer 7. Install correct spacer (use original spacer if no new parts are used) on intermediate shaft, with chamfer toward shoulder on shaft.

Fig. 3–15

A–02501

Cylinder Block

8. Install tapered bearing with small end toward the manifold block.

9. Install two alignment pins and new gasket.

10. Put assembled unit in a clean place until final assembly.

3–7.5 #1 Pump Assembly (Fig. 3–12) NOTE: If shaft bearings, shaft, valve block, housing or spacer were not installed new, use the same parts that were removed and go to step 2 below. If new parts are used, follow with step 1 below.

1. Bearing Preload Adjustment a. Install thickest bearing spacer over shaft with the chamfer toward the shoulder on shaft. b. Install bearing on shaft and against spacer. The small end of tapered bearing goes toward the manifold block. c. Install housing on manifold block without gasket and rotating group. Turn shaft while installing so that bearings are in correct position. d. Install screws and tighten to 2 in.–lbs. (0,23 Nm) torque. Tighten screws evenly so that the gap is as even as possible. e. Use a feeler gauge to check the gap. A tapered feeler gauge is very good for this purpose. Measure gap at four different places; add the four dimensions together and divide by four to get an average gap dimension.

EXAMPLE: (In Inches) minus plus plus equals

.150 measured thickness of thickest bearing spacer .027 average gap (from e. above) .002 ± .001 necessary preload .020 compressed thickness of gasket .146 ± .001 thickness of bearing spacer needed to give .001 to .003 bearing preload.

f. Remove six screws and remove housing from manifold block so that correct spacer gasket and internal parts can be installed.

Assemble Rotating Group 2. Install spring, two washers and snap ring in cylinder block (Fig. 3–10).

3. Install pin retainer about 1/4 inch (6,35 mm) below surface with opening away from large splines (Fig. 3–15).

4. Push three pins in cylinder block until each hits spring washer in block.

–3–24–

630, 631, 632 Loader Service Manual

5. Put spherical washer on top of three pins and install shoe plate and pistons.

Be sure all pistons slide freely in cylinder bores.

Install Rotating Group Into Housing 6. Hold shaft horizontal and slide rotating group into housing. Turn shaft until splines are in alignment.

7. Install correct spacer (use original spacer if no new parts are used) on intermediate shaft, with chamfer toward should on shaft.

8. Install tapered bearing with small end toward the manifold block.

9. Install two alignment pins and new gasket.

10. Put assembled unit in a clean place until final assembly.

3 - 7.6 Installing Pumps to Manifold Block 1. Install wafer plate locating pins in manifold block.

2. Install wafer plate (for #1 housing). Be sure wafer plate is flat against manifold block.

IMPORTANT

Be sure to use the correct wafer plate.

I–2172–0598

3. Put splined coupler on drive shaft.

4. Be sure gasket and alignment pins are in place and install housing on manifold block.

5. Install six screws and tighten to 23–26 ft.–lbs. (31–35 Nm) torque.

6. Turn vane pump shaft in intermediate shaft until it is against the shoulder; then turn vane pump shaft out 1/4 turn.

7. Put splined coupling over splines on intermediate shaft and vane pump shaft.

8. Install snap ring in groove in vane pump shaft.

9. Install wafer plate (for #2 housing). Be sure wafer plate is flat against manifold block. (See IMPORTANT statement above).

10. Be sure gasket and alignment pins are in place and install housing on manifold block. Turn vane pump shaft so that splines are in alignment.

11. Install six screws and tighten to 23–26 ft.–lbs. (31–35 Nm) torque.

12. Install large O–ring on end of #2 housing and install vane pump.

13. Install two screws to hold vane pump and tighten to 54–66 ft.–lbs. (73–89 Nm) torque.

NOTE: See Section 8 -Technical Data for type of fluid.

3–8 HYDROSTATIC MOTORS (630 S/N 15375 & Below and 632 S/N 15320 & Below)

IMPORTANT

Always keep hydraulic and hydrostatic parts clean. Clean outside of all assemblies before beginning repairs. Use plugs and caps to cover open ports. Dirt can quickly damage the system.

I–2173–0598

–3–25–

630, 631, 632 Loader Service Manual

3–8.1 Removing The Hydrostatic Motors 1. Raise the lift arms and install safety stop on the lift cylinder.

2. Raise the machine off the floor and support with four jackstands. Two under front axles and two under engine plate area.

WARNING

Put jackstands under the front axles and rear corners of frame before running the engine for service.

Failure to use jackstands can allow the machine to fall or move and cause injury or death.

W–2017–0286

3. Remove the ROPS: a. Remove holddown nuts and bolts; remove rear top grill.

C–02361R

Fig. 3–16 Removing Steering Linkage

b. Remove backhoe mounting brackets, if installed. c. Disconnect wiring harness at connector. d. Use hoist to remove ROPS (weight of ROPS is approximately 160 lbs.).

Charge Inlet Hose

e. Remove seat and shields.

4. Remove brake pedals and rod assembly.

5. Remove steering cross shaft with both steering levers (Fig. 3–16).

6. Remove front pump mounting bolts (through rubber bushings).

7. Remove charge inlet hose.

Install plug on the hose connector (Fig. 3–17).

8. Remove charge inlet elbow and install plug in pump open port.

9. Lift the front of the pump assembly and install a 1–1/2’’ block under one (1) pump mount (Fig. 3–17). This will give more spacer for cover removal.

Block 1–1/2’’

B–03019R

Fig. 3–17 Remove Charge Inlet Hose

10. Remove the covers under the hydrostatic motors (Fig. 3–18).

B–02985

Fig. 3–18

Remove Hydrostatic Motor Covers

11. Remove the front cover and rear transmission cover with brake caliper assembly (Fig. 3–19) BE CAREFUL–DO NOT DAMAGE GASKETS.

Lobes

12. Use special wrench (P/N 6559551), to loosen retainer nut on motor sprocket one and one–half (1–1/2) turns.

13. Rotate the retaining washer for the brake disc so that the brake disc can be taken off the sprocket teeth (Fig. 3–20).

C–02372R

Fig. 3–19 Remove Caliper Assy & Covers –3–26–

B–03021

Fig. 3–20 Remove Disc Brake 630, 631, 632 Loader Service Manual

14. Remove the brake disc.

If the discs can not be removed because of limited space between the sprocket retaining nuts, loosen the four (4) bolts on one hydrostatic motor and move the motor to make space for removing the brake discs.

15. Use a chain breaker tool to separate both front chains.

16. Remove the front chains from the motor sprockets.

17. Disconnect the four (4) high pressure hoses from the pump and motors.

18. Remove the hoses.

C–02373

Fig. 3–21 Remove Motor Mount Bolts

19. Install plugs in the motor and pump openings.

20. Remove the case drain hoses from the motors.

21. Use a lead pencil to draw an outline around the outside perimeter of motors.

This will aid as a reference to remove paint from chaincase later.

22. Remove the four (4) fastening bolts for motors (Fig. 3–21).

23. Hold motor at an angle and remove rear chains from the motor sprockets (Fig. 3–22).

3–8.2 Installing Hydrostatic Motors 1. Remove all paint from the motor mounting area as outlined by the lead pencil.

2. Install the motor with two (2) large openings facing toward the rear.

3. Put the rear chain over the motor sprocket (Fig. 3–22).

B–03020

Fig. 3–22 Remove Motor Connector Link

4. Install bolts, washers and use new locknuts into motor. Hand tighten the nuts.

5. Install the front drive chains. Use special tool (See Tool Catalog) or pliers to pull chain ends together (Fig. 3–22).

6. Install a new connector link from the outside of the chain (Fig. 3–23).

7. Use a vise grip with narrow jaws to press the connector link plate on the connector link pins.

8. Put a 5/8’’ thick steel block behind the new connector link. Use a ball peen hammer to peen the two (2) pins on the connector link (Fig. 3–24). (A special tool is also available for installing links (See Tool Catalog)).

9. Repeat this procedure for both motors.

B–03023

Fig. 3–23 Install Front Drive Chains

Lobes

5/8’’ Block

10. Install both brake discs over the sprockets on the motors.

NOTE: It may be necessary to temporarily put both brake discs on one motor sprocket to make room for tightening the four motor fastening bolts.

11. Turn the disc retaining washer so that the lobes on the disc are over the lobes of the retaining washer (Fig. 3–25).

C–02364

Fig. 3–24

Peening Connector Links

–3–27–

B–03022

Fig. 3–25 Disc Brake Installed 630, 631, 632 Loader Service Manual

Making The Special Tool For Holding Motor Sprockets (Fig. 3 - 26) a. Use an old brake disc.

2’’

b. Cut a piece of metal material approximately 9–1/2’’ long by 1–3/4” wide by 3/8’’, for a handle.

1–3/4’’

c. Weld the handle to the brake disc.

3/8’’

d. Put the handle so that 2’’ of metal handle is welded to the brake disc.

9–1/2’’

12. Put the special tool on the sprocket.

13. Use the special tool (6559556) for torque wrench to tighten sprocket retaining nuts to 300 ft.–lbs. (407 Nm) (Fig. 3–27). Keep the wrench straight in line with handle of special wrench.

B–03027

Fig. 3–26 Motor Wrench

NOTE: Ajust the torque for correct torque (See Table Below) when it is to be used with the special tool.

TABLE FOR VARIOUS LENGTHS OF TORQUE WRENCH Torque Wrench Length 12’’ 18’’ 24’’

Set Torque To 150 - 175 ft.–lbs.

180 - 210 ft.–lbs.

200 - 233 ft.–lbs.

14. After tightening the sprocket retaining nut, check location of the retaining washer to be sure the lobes are over the lobes on the brake disc. If not centered, loosen the retaining nut and adjust the washer.

C–02376

15. Tighten the four (4) motor mounting bolts to 120 ft.–lbs. (63 Nm) torque (Fig. 3–21).

Fig. 3–27 Tighten Sprocket Nuts

16. Install the case drain hoses.

17. Tighten the lock nuts on the case drain elbows.

Short Hose

Long Hose

18. Clean the four (4) high pressure hoses in solvent.

19. Install new o–rings on the four (4) hoses.

20. Install the hoses on the motors.

Hose Location (Fig. 3–28) NOTE: The front pump drives right side of BOBCAT. The rear drives left side.

B–03031

Fig. 3–28

Hose Location

a. Install the long hoses in top ports of the motors. b. Install the short hoses in the bottom ports of the motors.

21. Install one (1) long hose from the right side motor under the pump and connect it to the front left pump fitting.

22. Connect short hose on the right side motor to the right front fitting on the right side of the pump.

–3–28–

630, 631, 632 Loader Service Manual

23. Put left side motor long hose under the pump assembly and connect it to the right rear fitting of the pump.

24. Connect the short hose from the left motor to the left rear fitting of the pump.

25. Remove the plastic plug from the top of the hydrostatic pump (Charge Pressure Inlet). Install the elbow and connect the charge pressure hose to the elbow. Remove the block under the pump mount.

26. Install both transmission case covers and adjust the brakes according to brake adjustment procedure.

27. Install the two (2) bolts in the front pump mount.

NOTE: On early model loaders hold the pump assembly approximately 1’’ off the transmission case while tightening left pump mount, to compress the rubber bushing and prevent it from coming out of the mounting bracket.

NOTE: The newer Bobcats (630–S/N 14506 and Above; 631–S/N 11406 and Above; 632–S/N 14720 and Above) have the rubber bushings installed from the bottom of the mounting bracket. It is not necessary to hold the pump assembly up while tightening the bolts on these Bobcats.

28. Install the brake assembly.

29. After making brake adjustment, fill the hydraulic oil reservoir with oil (if level is low).

30. It will be necessary to remove air from the hydrostatic system.

31. Install steering cross shaft assembly and shield.

32. Install the shield and overhead guard.

3–8.3 To Remove Air From The Hydrostatic System (S/N 12999 & Below) a. Remove the large charg–pressure sender from the port block (on top of vane pump). Connect a clear plastic hose line from the opening to the hydraulic oil reservoir fill point.

(The loader must be on jackstands). b. Start the engine and operate the machine at full RPM and move both steering levers fully forward and backward for 3–5 minutes, until the oil returning to reservoir is flowing free of air. Stop the engine. c. Remove the plastic hose.d. Install the sender and connect the wire.

3–8.4 To Remove Air From The Hydrostatic System (S/N 13000 & Above) It is necessary to use a different procedure when removing air from the hydrostatic systems with the Char–Lynn Motors. (Be sure to put the loader on jackstands). a. With the engine running at a slow RPM and the brake engaged, move the steering levers forward a small amount to raise the pressure enough to open the shuttle which permits the charge oil to flow. This will remove air from the system. Move the steering levers backward (a small amount) to remove air from the other side of the system.

IMPORTANT

DO NOT move the steering levers to full forward or backward position.

This will cause damage to the motors.

I–2174–0598

–3–29–

630, 631, 632 Loader Service Manual

Also operate the lift arms and Bob–Tach to remove air from the hydraulic system.

Ball Shuttle Valve

Hex Plug

3–9 HYDROSTATIC MOTOR REPAIR (630 (S/N 15375 & Below) and 632 (S/N 15320 & Below) NOTE: Later Bobcats (630 - S/N 14244 and Above; 632 S/N 14307 and Above) have new type motors installed.

The improved motor has: • A larger shaft (1.5 inch. diameter).

CLOSED CENTER SYSTEM MOTOR

OPEN CENTER SYSTEM MOTOR

• Larger shaft bearings.

• Larger thrust bearings.

B–03389

Fig. 3–29

• A heavier housing.

Motor Identification

Later motors do not have a dust seal.

Service follows:

parts

are

available

as

• Complete motor (including both open and closed shuttle spools and instructions).

• Motor kit (includes shaft, bearings, housing, both shuttle spools and instructions. See parts manual and BTI #149 for more information.

Before you install a new motor, you must first make sure of the model and type of motor you are replacing. Look at the shaft end of the old motor to see if there is a ball in the bore in the end of the housing (open center system) or if there is a plug installed in the housing (closed center system) (Fig. 3–29).

Open Center Closed Center

B–03387

Fig. 3–30 Open And Closed Spools

B–03385

C–02362

Fig. 3–31 Removing Sprocket –3–30–

630, 631, 632 Loader Service Manual

If your old motor has a plug (closed center system), install the motor on your loader. (The new motor has the closed center system already installed).

If there is a ball (open center system), move the plug from the new motor, move the spring and shuttle valve and spring. Install the spring, the beveled shuttle valve and spring (See Fig. 3–30). Tighten the plug to 12–19 ft.–lbs. (16,3–25,8 Nm) torque.

3–9.1 Hydrostatic Motor Disassembly and Inspection NOTE: Make sure you check the end play of the shaft before disassembly (See Section 8 For Specifications).

End Cap B–02876

Fig. 3–32 Remove End Cap

1. Remove sprocket from motor shaft by removing nut and using a puller or a hydraulic press (Fig. 3–31).

S/N 12999 & Below

2. Remove bolts holding end cover to motor. Use a soft hammer to disassemble end cover and sleeve protector (Fig. 3–32).

3. Remove internal parts from motor (Fig. 3–33).

C–02013

S/N 13000 & Above Fig. 3–33

C–02388

Hydrostatic Motor Breakdown

–3–31–

630, 631, 632 Loader Service Manual

4. Slide coupling shaft from housing assembly (Fig. 3–34).

5. Remove seal from housing (Fig. 3–35). Remove snap ring and seal parts below outside seal (Fig. 3–36).

6. Use a press to carefully push against thrustwasher to remove needle bearings (Fig. 3–37).

7. Clean and inspect all parts for scratches, wear and damage (Fig. 3–38).

B–02841

*Fig. 3–34 Removing Drive Shaft

B–02877

Fig. 3–35 Removing Seal

Be sure inside check ball is free (Motors with model number MAE 24012, 24021 or 24024). Move the motor housing and the inner ball can be heard. Do not remove press fit ball (Fig. 3–33, Item 1).

3–9.2 Hydrostatic Motor Assembly 1. Clean all parts thoroughly and use all new seals and O–rings.

Put hydraulic fluid on parts during assembly.

2. Use seal installation tool. Install rubber sealing ring inside collar of tool with numbered side toward chamfer (Fig. 3–39).

(The lip of the seal must be toward the inside when installed).

3. Put installation collar into housing with chamfer toward housing (Fig. 3–39).

B–02842

Fig. 3–36 Removing Snap Ring & Seal

*

B–02872

Fig. 3–37 Removing Needle Bearings

*

4. Put installation sleeve into collar and push seal into housing (Fig. 3–39).

*

*

*

* Check These Areas For Wear

*

*

*

* B–02875

Fig. 3–38 Wear Areas –3–32–

630, 631, 632 Loader Service Manual

5. Remove installation sleeve and collar.

6. Install shim on seal, then install spacer and snap ring (Fig. 3–30). Be sure the snap ring is in position so that the lug on the spacer is not in the area between the snap ring ends.

NOTE: Be sure tapered edge of snap ring is towards spacer. Also put grease in the area between seal and the spacer.

Wiper Seal Snap Ring

Spacer

Installation Sleeve

Installation Collar Rubber Sealing Ring

B–02874

Fig. 3–40 Thrust Bearing

7. Install wiper seal (Fig. 3–39).

8. Install thrust bearings and washers (Fig. 3–40). The thrust washers must have the chamfers facing away from the bearing (Fig. 3–41).

A–02522

Fig. 3–39 Motor Seal Identification

Thrust Washer

Chamfer

Bearing

9. Install wide shaft bearings (Fig. 3–42). Push on numbered side only. The distance from machined surface of housing to numbered side of bearing must be 2.4–2.42 inches (60,96–61,47 mm) (Fig. 3–43).

10. Install narrow shaft bearing by pushing on numbered side. Distance from machined surface of housing to numbered side of bearing must be .150–.210 inches (3,81–5,334 mm).

11. Put housing in a vise. Put tape over key slot on shaft to prevent seal damage.

Install shaft in housing.

Bearing

Chamfer

Thrust Washer A–02679

Fig. 3–41 Location Of Washers

NOTE: Be sure to measure the length of the shuttle pin (Fig. 3–44) (S/N 12,999 & Below). The correct length is, minimum 1.455 inches (36,95 mm) and maximum 1.496 inches (37,97 mm). Replace the shuttle pin when it is not in this specification range.

B–02869

Fig. 3–42

Wide Shaft Bearing

Ball

Pin

B–02854

Fig. 3–43 Checking Bearing Location –3–33–

B–02857

Fig. 3–44 Ball & Pin (S/N 12999 & Below) 630, 631, 632 Loader Service Manual

12. Put the sealing ring in the groove in the housing with the bevel up (Fig. 3–45). Install ball and pin in housing (Fig. 3–44) (S/N 12999 & Below). Install springs, piston and spring (S/N 13000 & Above).

Holes Which Are To Be In Close Alignment

13. Install drive link in coupling shaft (Fig. 3–46). Be sure hole in drive link and hole in the side of the coupling shaft is in alignment to the nearest spline.

14. Install thrust bearing over shaft (Fig. 3–47).

NOTE: Alignment bolts can be used to aid in assembly.

B–02873

15. Install wear plate over shaft (Fig. 3–48).

Fig. 3–45 Housing Seal Ring

B–02895R

*Fig. 3–46 Installing Drive Link

16. Install stator ring and rotor assembly (Fig. 3–49).

17. Install manifold 3–50).

plate

(Fig.

B–02865

Fig. 3–47 Thrust Bearing Installation

B–02864

Fig. 3–49 Installing Stator Ring & Rotor –3–34–

B–02863

Fig. 3–48 Wear Plates

B–02866

Fig. 3–50 Manifold Plate Installation 630, 631, 632 Loader Service Manual

18. Install the manifold (Fig. 3–51).

19. Install commutator and bonded ring with flat side out (Fig. 3–52).

20. Install the commutator ring (Fig. 3–53).

21. Put grease on sealing ring and install protector sleeve (Fig. 3–54).

22. Install sealing ring on end cover and put cover on housing and protector sleeve. Fasten cover with bolts and tighten evenly to 50 ft.–lbs. (67,8 Nm) torque.

23. See Paragraph 3–8 for installing the hydrostatic motor.

B–02868

Fig. 3–51 ManifoldInstallation

B–02867R

Fig. 3–52 CommutatorInstallation

3–93 Start–Up Procedure For the Hydrostatic Motor NOTE: Loader must be off the floor.

1. Check the oil reservoir and add the correct oil as needed.

2. Start the engine. Check for leaks.

3. The motor must be run under load and at low RPM. 4. Operate the loader under a load condition (pushing dirt, etc.) for 10 minutes at no more than 1/2 throttle setting.

5. Stop the engine. Check the oil reservoir and add oil as needed.

B–02870R

*Fig. 3–53 Commutator Rind Installation

B–02891

Fig. 3–54 Installing Protector Sleeve –3–35–

630, 631, 632 Loader Service Manual

3–10 HYDROSTATIC MOTOR REPAIR (630 - S/N 15376 & Above, 631 and 632 - S/N 15321 & Above) 3–10.1 Disassembly Hydrostatic Motor

of

the

NOTE: Clean the outside of the motor before disassembly.

Keep all the parts of the motor clean.

1. Put the motor in a vise, holding it by the mounting flange with the shaft in the down position.

Put a mark across the motor sections for correct assembly (Fig. 3–55).

B–05117

Fig. 3–55 Marking Motor Sections

B–05118

Fig. 3–56 Removing Motor Bolts

2. Remove the four (4) bolts from the motor (Fig. 3–56).

3. Lift the valve housing (Fig. 3–57) straight up. If done carefully, the springs and balance plate will stay on the valve.

4. Put the valve housing on the bench with the open end up.

5. Remove the two (2) O–rings (small and large) (Fig. 3–58) from the valve housing.

B–05120

Fig. 3–57 Removing Valve Housing

B–05126

Fig. 3–58 Removing O–rings

NOTE: Machine surface must be put on a soft cloth.

6. Remove the plug from the valve housing (Fig. 3–59).

7. Remove the spring, dash pot and poppet (Fig. 3–60).

8. Use a punch, remove the poppet, spring, o–ring dash pot and the plug and the shuttle (Fig. 3–61).

9. Remove the two (2) springs from the balance plate (Fig. 3–62).

B–05127

Fig. 3–59 Removing Plug

B–05129

Fig. 3–61 Remving Shuttle Valve –3–36–

B–05128

Fig. 3–60 Removing Springs

B–05124

Fig. 3–62 Removing Spring From Plate 630, 631, 632 Loader Service Manual

10. Remove the balance plate.

11. Remove the seals from the balance plate (Fig. 3–63).

12. Remove the valve (Fig. 3–64).

13. Remove the valve plate (Fig. 3–65).

14. Remove the valve drive (Fig. 3–66).

15. Remove the geroler (Fig. 3–67).

Make sure the rollers are kept in the geroler.

B–05130

Fig. 3–63 Balance Plate Seals

B–05134

Fig. 3–64 Removing The Valve

16. Remove the two (2) O–rings from the geroler.

17. Remove the drive shaft (Fig. 3–68).

18. Remove the O–rings (large and small) from the bearing housing (Fig. 3–69).

The tool listed will be needed to the following procedure.

MEL–1187 – 5/16’’ Special Socket 19. Turn the bearing housing over in the vise and remove the eight bolts (Fig. 3–70).

B–05123

Fig. 3–65 Removing Valve Plate

B–05122

Fig. 3–66 Removing Valve Drive

20. Using a plastic hammer, tap the mounting flange from the housing.

B–05121

Fig. 3–67 Removing The Geroler

B–05119

Fig. 3–68 Removing Drive Shaft

B–05125

Fig. 3–69 Removing The O–rings –3–37–

B–05132

Fig. 3–70 Removing The Bolts 630, 631, 632 Loader Service Manual

NOTE: To remove the seal and back–up washer for the Models 109–1052–005 and below see figures 3–71 & 3–72. To remove the dust seal and inner seal for the Models 109–1052–006 and above see figures 3–73 & 3–74.

21. Remove the back–up washer and seal from the mounting flange (Fig. 3–71 & 3–72).

22. Remove the dust seal and inner seal from the mounting flange (Fig. 3–73 & 3–74).

B–05141

Fig. 3–71 Removing Back–Up Washer

B–05142

Fig. 3–72 Removing Seal

23. Remove the large o–ring from the mounting flange (Fig. 3–75).

24. Use a press to remove the shaft and bearing assembly (Fig. 3–76).

25. Remove the shaft surface seal from the bore of the bearing housing (Fig. 3–78).

B–06769

Fig. 3–73 Removing Dust Seal

Model 109–1052–005 & Below 3–1/2’’ O–ring

B–06768

Fig. 3–74 Removing Inner Seal

Shaft Face Seal Square Key

Mounting Flange Quad Ring

Bearing Housing Shaft & Bearing Assembly Back–Up Washer

Cap Screws (8)

D–1439R

Mounting Flange Inner Seal Dust Seal

D–01650

Fig. 3–75 Drive End For The Hydrostatic Motor –3–38–

630, 631, 632 Loader Service Manual

3–10.2 Hydrostatic Inspection

Motor

Before the hydrostatic motor is assembled, check the following items and replace as needed. a. Check the geroler (Fig. 3–78). b. Check the geroler rollers (Fig. 3–79). c. Check the rotor.

B–05140

d. Check the valve plate (Fig. 3–80).

Fig. 3–77 Removing Shaft Seal

e. Check the valve (Fig. 3–81 & 3–82). f. Check the balance plate (Fig. 3–83).

B–05135

Fig. 3–76 Removing The Shaft

g. Check the valve drive shaft and the main drive shaft for wear. h. Check the end plate for scratches. i. Check the shuttle valve assembly (Fig. 3–84).

Check all the contact surfaces. Replace any parts that have scratches or are worn that can cause leakage.

Clean all the parts in solvent and use air pressure to dry the parts. DO NOT use cloth or paper because small pieces of material can get into the hydrostatic system and cause damage. DO NOT use sandpaper or a file to remove scratches on any of the parts.

B–04643

Fig. 3–78 Checking Geroler

B–04631

Fig. 3–79 Checking Rollers

B–04634

Fig. 3–80 Checking Valve Plate

B–04638

Fig. 3–81

Checking Valve

–3–39–

B–04626

Fig. 3–82 Checking Valve 630, 631, 632 Loader Service Manual

3–10.3 Assembly of the Hydrostatic Motor (Fig. 3–85) The tools listed will be needed to do the following procedure: MEL–1015 Seal Tool (Model 109–1052–006 & Above) MEL–1182 Socket 5/16’’)

IMPORTANT

B–04625

Fig. 3–83 Checking Blanace Plate Use grease such as Dow Corning #44 or Vaseline petroleum jelly to hold seals, O–rings and bearings in position during assembly.

I–2010–0597

NOTE: Always use a NEW seal kit when assembling the hydrostatic motor.

A–02774

Fig. 3–84 Shuttle Valve Assembly

Back–Up Washer 4 2

3

5 D–01439R

Inner Seal

Dust Seal

1

2 5 D–01650

D–01650

Fig. 3–85 Hydrostatic Motor Assembly –3–40–

630, 631, 632 Loader Service Manual

1. Put the bearing housing on a smooth surface with the largest opening up.

2. Take the largest diameter half of the seal tool and lubricate the inside.

3. Install the seal tool into the bearing housing (Fig. 3–86).

4. Install the shaft face seal (with the inside edge up) into the seal tool.

5. Install the small diameter half of the seal tool and push the seal into the correct position (Fig. 3–87).

B–05138

Fig. 3–86 Installing Seal Tool

B–05137

Fig. 3–87 Installing The Seal

6. Press the shaft and the bearing assembly into the housing (Fig. 3–88). Be careful not to damage the shaft seal. Turn the shaft several times to make sure that the shaft is free.

NOTE: If the shaft and bearing assembly is damaged it must be replaced as a complete unit. There are no replacement parts in the shaft bearing assembly.

7. Lubricate the 3–1/2’’ (88,9 mm) diameter O–ring (Fig. 3–85, Item 1). Install the O–ring in the bearing housing (Item 2).

8. Model 109–1052–005 & Below Only: Install the back–up washer (Fig. 3–85, Item 3) and the seal (Item 4) into the mounting flange. The seal must be toward the inside of the motor. Lubricate the inside of the seal.

Model 109–1052–006 & Above Only: Install the inner seal, using the tool, into the mounting flange (Fig. 3–89). Install the dust seal, using the tool, into the outside of the mounting flange (Fig. 3–90).

B–05136

Fig. 3–88 Installing Shaft Assembly

B–06770

Fig. 3–89 Installing Inner Seal –3–41–

B–06771

Fig. 3–90 Installing Dust Seal 630, 631, 632 Loader Service Manual

9. Turn the mounting flange while installing it over the shaft. Be careful not to damage the seals.

10. Put oil on the threads of the eight bolts (Fig. 3–85, Item 5). Install the bolts in the mounting flange and tighten them with your hand only.

11. Put the motor in a vise and tighten the bolts evenly to 250 in.–lbs. (28 Nm) torque. Use the correct tightening sequence (Fig. 3–91).

12. Install the key in the keyway of the shaft.

13. Put the motor in a vise with the output shaft down (Clamp the sides of the mounting flange only).

B–03042R

14. Put a small amount of oil on the output shaft.

Fig. 3–91 Tightening Sequence

15. Put petroleum jelly on the 3–1/2’’ (88,9 mm) diameter O–ring and install it in the outer groove in the bearing housing.

16. Install the main drive in the output shaft with the longer splined end going in first (Fig. 3–92).

17. Put petroleum jelly on the two 1/4’’ (6,35 mm) diameter O–rings. Install the O–rings, one on each side of the geroler ring.

B–05119

Fig. 3–92

–3–42–

Installing Drive Shaft

630, 631, 632 Loader Service Manual

The timing of the motor controls the direction of rotation of the drive shaft of the motor. The timing parts of the motor are as follows (Fig. 3–93):

Rotate Valve Clockwise 1/2 Tooth to Engage Spline Anyone of 6 Ports Open to Outside of Valve

(a) Geroler (Item 1)

4

(b) Valve Drive (Item 2) (c) Valve Plate (Item 3)

Largest Opening

(d) Valve (Item 4) 18. Find the largest opening between the geroler star and the geroler ring and mark the outside of the geroler ring at that location (Fig. 3–93).

Case Drain Hole (2)

19. Align the case drain hole and the three pressure holes in the geroler ring with the same holes in the mounting flange and install the geroler assembly.

Make sure to keep the rollers in position.

2 3 Valve Drive

20. Install the valve drive in the geroler (Fig. 3–93, Item 2).

NOTE: When looking through the 7 holes (Fig. 3–93, Item 5) in the valve plate, if you see a roller in all the holes, it is assembled incorrectly, the motor will lock–up.

Valve

Valve Plate

1 Pressure Relief Hole (3) Geroler Ring

Geroler Star C–02384

Fig. 3–93 Timing The Motor

21. Put petroleum jelly on the 3–1/2’’ (88,9 mm) diameter O–ring. Install the O–ring on the valve plate.

Pressure In

22. Align the case drain hole in the valve plate with the case drain hole in the geroler. Install the valve plate with the O–ring toward the geroler.

NOTE: Make sure the slot opening of the valve plate is in alignment with the largest opening of the geroler.

23. Align the valve on the valve drive so that anyone of the side openings is in alignment with the mark you made on the outside of the geroler. Turn the valve clockwise 1/2 tooth to engage the drive. This will give the rotation shown when pressurized (Fig. 3–94).

Clockwise Rotation Pressure In

Counterclockwise Rotation E–01442

Fig. 3–94 Rotation Of Motor –3–43–

630, 631, 632 Loader Service Manual

24. Install the poppet, spring, dampener, O–ring and plug in the valve housing.

25. Install the shuttle (Fig. 3–95), poppet, dampener and spring in the other side of the housing.

26. Install the new O–ring on the plug and install the plug and tighten.

27. Put grease on the 1/4’’ (6,35 mm) O–rings and install them on the housing (Fig. 3–96).

B–04645

Fig. 3–95 Installing Shuttle Valve

B–05126

Fig. 3–96 Installing O–rings

28. Install the spring (Fig. 3–97) in the valve housing.

29. Put grease on the inner and outer seals (Fig. 3–98, Items 1 & 2) and install the seals onto the balance plate. Make sure they are in the position shown in figure 3–98.

30. Install the pins in the balance plate and install the assembly on the springs (Fig. 3–99).

31. Make sure the case drain holes are in alignment. Install the valve housing by putting your finger through the port in the housing to hold the balance plate assembly in position (Fig. 3–100).

32. Check all the surfaces that contact each other to make sure all the O–rings are in position.

B–04644

Fig. 3–97 Installing Springs

Inner Seal Pin

Outer Seal

Balance Plate B–03046

Fig. 3–98 Balance Plate Assembly

B–04630

Fig. 3–99

Installing Balance Plate

–3–44–

B–04649

Fig. 3–100 Installing Housing 630, 631, 632 Loader Service Manual

33. Install the bolts. Use the sequence (Fig. 3–101) and tighten the bolts to 50 ft.–lbs. (67 Nm) torque (Fig. 3–102).

4

1

2

3

3 - 10.4 Installing the Hydrostatic Motor 1. Install the motor into the chaincase.

2. Install the four bolts and tighten to 65–70 ft.–lbs. (88–95 Nm) torque.

3. Connect the hoses to the correct ports of the hydrostatic motor (Fig. 3–102a). (Short hoses to the upper ports, long hoses to lower ports).

4. Tighten the hoses. Install the motor cover (Fig. 3–103).

A–02658

5. Install the wheels on the loader.

Fig. 3–101 Tighten Sequence

6. Check the hydraulic/hydrostatic reservoir fluid level. Add fluid as needed.

3–10.5 Start–Up Procedure for the Hydrostatic Motor Because of the close tolerances in the hydrostatic motors it is very important that the motor is NOT OPERATED WITHOUT A LOAD after being repaired.

The motor MUST BE PUT UNDER FULL LOAD condition for at least 10 minutes.

FULL LOAD can be accomplished by pushing some heavy object or material.

When driving the loader under a no load condition to a full load condition use a low engine RPM and only a small amount movement of the steering levers. Keep the no load condition to a minimum until the break–in period is completed.

3–11 STEERING CONTROLS B–05118

3–11.1 Installing Steering Linkages – 630–S/N 15300 & Below; 631–S/N 12253 & Below; 632–S/N 15450 & Below;

Fig. 3–102 Tighten Bolts

1. Push the rubber bushings into the pintle levers (one each way).

2. Install pintle levers on the front and rear pintle shafts of the pump, aligning the keys with the keyways. The lobes of the pintle levers go toward the front of the loader.

3. Leave enough clearance so the levers are 1/8’’ away from the bolts in the pintle covers.

FRONT OF LOADER

C–02767

*Fig. 3–102a Hose Routing

B–03256

Fig. 3–103 Installing Motor Cover –3–45–

630, 631, 632 Loader Service Manual

NOTE: There are three plastic washers; two washers are the same and one is different. The different washer goes on the rear pintle shaft (Fig. 3–104).

Two Washers Between Centering Bar & Pintle Bar Centering Bar One Plastic Washer

4. Install the one (different) plastic washer in the rear slot of the centering bar.

5. Install one of the two plastic washers that are the same on the front pintle shaft.

Brass Collar Two Plastic Washers

6. Install centering bar on the transmission pump.

7.

Retainer Clip

Install the other plastic washer on front pump shaft.

8. Push the retainers on both pump shafts. The clearance between shoulder of pintle levers and retainer clips must be .01–.02 (Fig. 3–105).

B–03028R

Fig. 3–104

Adjusting Neutral Position

.01’’ – .02’’ (0,254 – 0,508 mm)

9. Install centering bolt, spring and brass collar on centering bar and fasten centering bolt to pump mount with locknut.

Pintle Lever

10. Tighten locknut until spring is 2–9/16 to 2–5/8’’ (66,04 mm) long.

11. Tighten jam nut against the locknut.

Retainer

To install steering linkages: 12. Fasten steering linkages to the pintle levers. DO NOT tighten bolts all the way yet (Fig. 3–106).

13. Fasten steering linkage to the steering shaft assembly. DO NOT tighten the bolts all the way yet.

14. Install right steering lever and connect auxiliary linkage. Tighten nut to 14 ft.–lbs. (19 Nm) torque.

Plastic Guide Centering B–03213 Bar Fig. 3–105 Installing Retainer

15. Install elbow and charge pressure inlet hose to top of hydrostatic pump.

16. Add fluid to the correct level and see that all hoses and tubelines are connected and tightened.

17. Push the rubber bushings into the foot pedals from the center of the pedal outward.

18. Assemble pedal and mounting bracket using new hairpin fasteners and pivot pins.

19. Install the shields over the steering levers and tighten mounting bolts.

20. Install the foot pedal assemblies.

21. Connect linkages to foot pedals.

B–03025

Fig. 3–106 Installing Steering Linkage –3–46–

630, 631, 632 Loader Service Manual

22. Adjust foot pedals (Fig. 3–107).

This Point Of Foot Pedal Must Be Even With Top Of Transmission Case

23. Install the operator cab.

24. Connect wiring harness.

25. Install 2 jackstands under front axles and 2 under engine compartment.

Loader must be restrained for some service and repair. When balance of loader is changed by removal of lift arms or engine, or when it is necessary to rotate axles, jackstands should be put under both front axles and both rear corners of frame. Blocks by wheels can be climbed and do not stop loader.

WARNING

W–2310–0398 A–02415R

Fig. 3–107 Adjusting Pedals

26. Start engine. Run engine at full throttle.

To adjust for neutral position: (See Section 3–3, Page 3–16) 3–11.2 Installing Steering Linkages; 630 (S/N 15301 & Above; 631 (S/N 12254 & Above); 632 (S/N 15451 & Above) Fig. 3–71) 1. Install the (2) cams (Fig. 3–108, Item 1) on the pintle levers (Item 2) using a bolt (3/8 x 1–1/2’’ (Item 3) for the top can and a bolt (3/8 x 3/4’’) (Item 4) for the bottom can. Tighten the bolts to 25–28 ft.–lbs. (24–28 Nm) torque.

2. Install the bolt (3/8 x 1–3/4’’) (Item 5) in the pintle lever, do not tighten.

8

2

1 20

3

12

14 15 16

13

5 4

17

10 7

11 3 5

6

1

2

18 9

8

4 Fig. 3–108

9

E–01294

Steering Linkage Assembly

–3–47–

630, 631, 632 Loader Service Manual

3. Install the adjustment bars (Item 6) on the centering bar (Item 7) and tighten with your hand only.

Steering Linkages

630,631,632ServiceManual#6556454–HydrostaticSystemSection

4. Install (press) the bushings (Item 8) into the pintle levers (Item 2) (one from each direction).

5. Install the key (Item 9) and the pintle lever assembly over the shaft on the hydrostatic pump.

6. Install the inner teflon washer (Item 10) on the shaft of the pump.

7. Install the teflon guide (Item 11) in the centering bar (Item 7).

8. Lubricate the cam surface (Item 1) (on the pintle lever) with grease.

Adjust Bar Tight Against Both Cams

Pintle Bar

Cam

Adjustment Bar

2.55–2.65’’ (64,8–67,3 mm) C–02544

Fig. 3–109 Centering Spring Adjustment

13. Install the centering bar (Item 7) on the shafts of the pump.

14. Install the outer teflon washer (Item 12) over the shaft next to the centering bar.

15. Install the two collars (Item 13) over the pump shaft and into the pintle levers.

NOTE: Position the pintle levers on the pump shaft so they are toward the pump housing as far as possible but so that there is clearance between the levers and the hydrostatic pump housing.

9. Make sure the steering assembly is in a center position. Tighten the bolts (Item 5) to 18–20 ft.–lbs (24–27 Nm) torque.

10. Install the centering bolt (Item 14), spring (Item 15), washer (Item 16), nut (Item 17) and lock nut (Item 18).

11. Adjust the centering bolt (Fig. 3–109) so that there is 2.55–2.65’’ (64,8–67,3 mm) of spring between the mounting bracket and the head of the centering bolt.

12. Start engine and run at full throttle.

To adjust the steering linkages for neutral position see Section 3–3, Page 3–16.

–3–48–

630, 631, 632 Loader Service Manual

DRIVE SYSTEM Paragraph Number AXLE AND BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BRAKE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4–2 4–3 4–1

Page Number 4–1 4–2 4–1

DRIVE SYSTEM

–4––1–

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–4–0–

630, 631, 632 Loader Service Manual

4 DRIVE SYSTEM 4–1 FINAL DRIVE 4–1.1 Drive Chains The drive chains are endless (do not have connector links). Use a new connector link if chain separation is necessary. Put paint on connector link for future identification.

NOTE: For detailed chain replacement (See Section 3, Pages 3–26 and 3–27).

B–02814

Fig. 4–A

WARNING

Removing Axle Nut

B–02811

Fig. 4–B Removing Axle

Put jackstands under the front axles and rear corners of the frame before running the engine for service.

Failure to use jackstands can allow the machine to fall or move and cause injury or death.

W–2017–0286

1. Remove the seat assembly and chaincase covers.

2. Separate the chain (at connector link if there is one0> 3. Remove the chain and install new chain (See Pages 3–26 and 3–27, Paragraph 3–8).

Fig. 4–C Outer Halves

4. Check fluid level and add as necessary.

4–2 AXLE AND BEARINGS Removal, assembly and installation are the same for all four axles.

4–2.1 Axle Bearing Removal

WARNING

Put jackstands under the front axles and rear corners of the frame before running the engine for service.

Failure to use jackstands can allow the machine to fall or move and cause injury or death.

W–2017–0286

Fig. 4–D Installing Spring

1. Remove tire and wheel assembly.

2. Remove bolt, washer and sprocket (Fig. 4–A).

3. Remove the axle from the inner bearing (Fig. 4–B).

4. Remove the outside bearing race (Fig. 4–D).

5. Remove the inside bearing race (Fig. 4–D).

Bearing 6. Remove the bearing from the axle (Fig. 4–1).

7. Clean and inspect all parts for wear or damage.

B–02813

Fig. 4–1 Removing Outer Bearing –4–1–

630, 631, 632 Loader Service Manual

4–2.2 Assembly and Installation 1. Install a new seal on the axle with the open side toward the chaincase.

Bearing

2. Push the bearing onto the axle (Fig. 4–2).

NOTE: To get the correct end play, the bearing setting at the axles must be .0021’’ to .010’’ (0,005 to 0,266 mm) preload.

Recessed washers .005’’ to .010’’ (0,13 to 0,25 mm) are available to give correct axle end play.

The following tool must be needed to install the bearing races.

B–02810

Fig. 4–2 Installing Outer Bearing

B–07679

Fig. 4–3 Installing Outer Race

MEL1202 – Master Axle Bearing Race Service Set 3. Install the outside bearing race (Fig. 4–3).

4. Install the inside bearing race (Fig. 4–4).

5. Pack each bearing with wheel bearing lubricant.

6. Install the sprocket into the chaincase with the chain in position on the sprocket.

B–07680

Fig. 4–4 Installing Inner Race NOTE: The wide part of sprocket hub goes toward the inside for front axles and toward the outside for rear axles.

B–02770

Fig. 4–5 Inner Halves

7. Install axle, inside bearing and sprocket.

The following tool will be needed to install the axle seal.

MEL1051 – Axle Seal Tool 8. Install the inner halves of the installation tool (Fig. 4–6).

9. Install the outer halves of the installation tool (Fig. 4–6).

10. Install the spring (Fig. 4–7).

11. Lubricate the axle seals with grease before installing them into the axle housing.

B–02774

Fig. 4–6 Outer Halves 12. Use a hammer to hit the axle flange until the installation tool is in contact with both the axle flange and the axle housing.

13. Remove the installation tool.

14. Tighten the axle bolt.

15. Install covers on chaincase and install the seat assembly.

4–3 BRAKE INSTALLATION 1. Remove the seat and seat plate, controls shield, steering levers and linkages, both transmission covers and brake/puck assembly.

IMPORTANT

Be careful not to damage the gasket when removing the transmission covers.

I–2118–1196

–4–2–

Spring B–02772

Fig. 4–7 Installing Spring 630, 631, 632 Loader Service Manual

NOTE: It will be easier to install brake assembly if you remove the front mounting bolts for the hydrostatic pump, then install spacer under pump to hold pump up.

To remove brake discs: 2. Use special wrench (Kit #6559551) to loosen nuts on motor sprockets 1–1/2 turns (Fig. 4–8).

NOTE: If your cannot remove sprocket nut without the sprocket turning, you must make a wrench to hold the sprocket (Fig. 4–9). a. Use one old brake disc. b. Cut a piece of metal 9–1/2’’ (241) long x 1–3/4’’ (44) wide x 3/8’’ (9,5) thick to use for a handle (approximate dimensions).

C–02376

Fig. 4–8 Loosen Sprocket Nut

c. Weld the handle to the disc so the 2’’ of metal is welded to the disc.

3. Turn retaining washers so that the brake disc can be removed from sprocket teeth (Fig. 4–10).

2’’

4. Remove brake disc.

1–3/4’’

NOTE: If brake discs cannot be removed between the two sprockets nuts, it will be necessary to loosen one motor from the transmission case and move the motor out 1/4’’ (6,4).

3/8’’

To install brake discs: NOTE: Be sure that the brake discs are clean, free of rust and scratches before installing them.

9–1/2’’

5. Install two new brake disc over the sprocket.

B–03027

Fig. 4–9 Special Tool

6. Put special tool (Fig. 4–9) onto sprocket.

7. Use special wrenches and a torque wrench to tighten sprocket nuts to 300 ft.–lbs. (407 Nm) torque (See NOTE Below).

Lobe

Washer

NOTE: When you use the special wrench (6559551) you must use different torque settings according to the length of your torque wrench.

TABLE FOR VARIOUS LENGTHS OF TORQUE WRENCHES Torque Wrench Length

Set Torque To

12 inches long 18 inches long 24 inches long

150 ft.–lbs. (203 Nm) 180 ft.–lbs. (244 Nm) 200 ft.–lbs. (271 Nm)

8. After tightening the sprocket nut, check to see that the brake disc will not come off the sprocket. If the disc will come off, loosen the sprocket nut and turn the washer so that the lobes of the washer keep the disc on the sprocket 9Fig. 4–11).

9. If one motor was loosened, tighten the four nuts to 120 ft.–lbs. (163 Nm) torque.

Brake Disc Fig. 4–10

B–03021 Removing Brake Disc

Lobe

Washer

To install new brake/puck assembly: 10. Remove the old brake/puck assembly from transmission cover.

Brake Disc Fig. 4–11 Holding Brake Disc –4–3–

B–03022

630, 631, 632 Loader Service Manual

11. Install the new brake block on the transmission cover.

Cover

12. Install the pucks into casting.

Install the last puck into puck retainer and put into casting.

13. Put a new O–ring on the cam. Put oil on the O–ring. Install the cam in the casting from the top.

14. Put the brake/puck assembly and transmission cover over the brake discs. The gaskets will be aligned later (Fig. 4–12).

Brake Disc C–02372R

Fig. 4–12 Installing Brake/Cover

15. Turn the cam counterclockwise with a vise–grip pliers to force the pucks against the discs.

16. While holding the pucks against the discs, align the transmission cover so that the discs are exactly in the center of the sprocket teeth.

17. Align the gasket and install cover bolts and tighten to 20 ft.–lbs. (27 Nm) torque.

1/4’’ Spacer Adjusting Nut

NOTE: Remove spacer from under pump. Install bolts into rubber bushings while holding pump up to prevent bushings from being pushed out.

18. Be sure pucks are tight against discs; then install brake lever on the cam with the lever as far clockwise as possible (against the right pump mount.

19. Install front cover and tighten bolts to 20 ft.–lbs. (27 Nm) torque.

C–02366

Fig. 4–13 Using Spacer

20. Install bar and bolt on cam.

21. Tighten bolt to 15 ft.–lbs. (20 Nm) torque.

22. Assemble brake pedal and rod.

–4–4–

630, 631, 632 Loader Service Manual

23. Install pedal on front cover.

24. Install brake rod into hole in brake lever.

25. Use prybar to carefully turn brake lever counterclockwise far enough to install spacer (big nut) and lock nut on brake rod.

26. Put a 1/4’’ (6,35) additional spacer between the lock nut and spacer nut (Fig. 4–13).

A–02517R

27. Tighten lock nut until 1/2’’ (12,7) of threads are showing past end of lock nut (Fig. 4–12).

Fig. 4–14

Adjusting The Brake Lever

28. Leave 1/4’’ spacer in place (Fig. 4–13).

29. Hold bar parallel to the tank wall and tighten bolt to 70 ft.–lbs. (95 Nm) torque (Fig. 4–14).

30. Remove the 1/4’’ additional spacer.

31. Connect one end of the spring to bar on cam. Connect other end of small strap and fasten to the right center bolt for chaincase covers. Tighten bolt to 20 ft.–lbs. (27 Nm) torque.

32. Check pedal operation in locked and unlocked positions.

33. Spring must allow 1/4’’ freeplay in lever when pedal is in unlocked position.

34. Install steering levers and linkage.

35. Install seat, seat plate and control shields.

–4–5–

630, 631, 632 Loader Service Manual

630,631,632ServiceManual#6556454–DriveSystemSection

–4–6–

630, 631, 632 Loader Service Manual

MAIN FRAME Paragraph Number BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BOB–TACH FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAIN FRAME TO UPRIGHT FRAME BOLTS . . . . . . . . . .

PIVOT PIN REPLACEMENT OF THE LIFT ARMS . . . . . .

ROPS REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . .

5–3 5–6 5–5 5–4 5–2 5–1

Page Number 5–2 5–3 5–3 5–3 5–1 5–1

MAIN FRAME

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630, 631, 632 Loader Service Manual

5 MAIN FRAME 5–1 ROPS REMOVAL INSTALLATION (Fig. 5–1)

AND

1. Stop engine and activate hydraulic controls to release hydraulic pressure in system.

Remove Bolts

2. Fasten a chain hoist to ROPS. 3. Remove two bolts from lower front corners of ROPS. 4. Remove two bolts from upper rear corners of ROPS. 5. Disconnect wiring harness.

6. Lift ROPS and remove it from Bobcat.

IMPORTANT

Remove Bolts Fig. 5–1 Removing ROPS

B–02800

Be sure to install correct washer on bottom of rubber mount.

I–2167–0498

When installing ROPS, be sure to install correct ports as shown in figure 5–2.

5–2 PIVOT PIN REPLACEMENT ON THE LIFT ARMS (Fig. 5–3)

WARNING

Do not remove lift arms without putting support under rear of Bobcat.

W–2314–0498

1. Stop engine and activate hydraulic controls to release hydraulic pressure in system.

D–01369

2. Fasten a chain hoist to lift arms.

Fig. 5–2

Installing Rubber Mount

3. Remove locking bolt in pivot pin.

4. Use a punch and hammer to remove pivot pins.

5. Install pivot pins in reverse order of removal.

Remove all pivot pins in the same manner.

WARNING

Be careful when removing pins in lift cylinder. Keep cylinder from falling when removing pins.

W–2315–0498

Pivot Pins

B–02801

Fig. 5–3 –5–1–

Pivot Pin Replacement

630, 631, 632 Loader Service Manual

5–3 BOB–TACH 5–3.1 Checking Bob–Tach Wedges (Fig. 5–4) 1. Install an attachment on Bobcat.

2. Engage locking levers.

3. Make replacement if wedges are not at least 1/4 inch (6,35 mm) through notches in attachment.

NOTE: Adjustment can not be made to Bob–Tach wedges.

Wedge Must Extend Through Slot

5–3.2 Bob–Tach Removal (Fig. 5–5) 1. Lower lift arms and Bob–Tach to ground.

lower

B–03893

2. Stop engine and activate hydraulic controls to release hydraulic pressure from system.

Fig. 5–4 Checking Wedges

B–02791

Fig. 5–5

Removing Bob–Tach

3. Remove locking bolt and remove pin from rod end of tilt cylinder.

4. Remove bolts and washers from Bob–Tach pivot pins.

5. Use hammer and punch to push pivot pins into Bob–Tach frame.

6. Remove Bob–Tach.

1

5–3.3 Bob–Tach Installation 1. Install Bob–Tach between lift arms.

2. Install pivot pins in Bob–Tach and use a hammer to push pins into lift arms.

3. Install bolts and washers in ends of pivot pins.

4. Tighten bolts to 125–140 ft.–lbs. (170–190 Nm) torque.

5. Install pin in Bob–Tach and pin rod end of tilt cylinder.

D–01280R

6. Install locking bolt in pin and tighten to 35–45 ft.–lbs. (48–61 Nm) torque.

Fig. 5–6

5–3.4 Bob–Tach Pins

Bob–Tach Pins

Lift Arm Stops

Check bolts (Fig. 5–6, Item 1) at the 30 hour inspection and every 100 hours.

Tighten bolts to 125–140 ft.–lbs.

(170–190 Nm) torque.

5–3.5 Bob–Tach Over–Center Stop Install mechanical stops on the Bob–Tach and lift arms when the Bob–Tach goes over–center when tilted fully forward.

Install the kit (P/N 6560898) to prevent damage to the tilt cylinder parts (Fig. 5–7).

Bob–Tach Stops

D–01488

Fig. 5–7 Bob–Tach Over–Center Stops –5–2–

630, 631, 632 Loader Service Manual

5–4 MAIN FRAME TO UPRIGHT FRAME BOLTS Check bolts (Fig. 5–8, Item 1) at the Pre–Delivery Inspection and every 100 hours. Tighten bolts to 65–70 ft.–lbs. (88–95 Nm) torque.

1

5–5 LIFT ARMS The lift arms may crack at the ‘‘knee’’ from heavy service duty (Fig. 5–9). If any cracks show at the ‘‘knee’’, order a kit from Chicago Central Parts to repair the lift arms.

Instructions are included with the kit to show installation procedure.

E–01172

Fig. 5–8 Axle Housing To Upright Frame Bolts

B–03474

Fig. 5–9

Lift Arms

–5–3–

630, 631, 632 Loader Service Manual

630,631,632ServiceManual#6556454–MainFrameSection

–5–4–

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ELECTRICAL SYSTEM Paragraph Number ALTERNATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CIRCUIT (631 & 632) . . . . . . . . . . . . . . . . . .

ELECTRICAL GENERAL INFORMATION . . . . . . . . . . . . .

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

USING AN EXTRA BATTERY . . . . . . . . . . . . . . . . . . . . . . . .

6–4 6–3 6–2 6–5 6–1

Page Number 6–24 6–21 6–19 6–26 6–1

ELECTRICAL SYSTEM

–6––1–

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–6–0–

630, 631, 632 Loader Service Manual

6 ELECTRICAL SYSTEM 6–1 USING AN EXTRA BATTERY If it is necessary to use an extra battery to strt the engine, be careful. This is a two person operation. There must be one person in the operator’s seat and one person to connect and disconnect the battery cables.

WARNING

You must wear goggles when you work near batteries. Do not let acid make contact with you body or clothing.

W–2312–0498

1. The ignition must be in the ‘‘OFF’’ position.

2. The battery to be used must be of the same voltage.

3. Battery terminals have identification marks. The positive terminal is marked (+) and the negative terminal is marked (–).

4. The negative terminal (–) of the battery must be connected to the engine or loader.

WARNING

Never connect an extra battery to the battery in the machine if the battery fluid has become solid because of freezing temperatures.

W–2319–0598

5. Connect the end of the first cable to the positive (+) of the extra battery.

Connect the other end of the same cable to the positive terminal (+) of the loader battery.

6. Connect the end of the second cable to the negative terminal (–) of the extra battery. Connect the other end of the second cable to the engine. DO NOT connect directly to the negative terminal (–) of the loader battery. Connecting cable directly to the negative terminal (–) of the loader battery can cause spark and destroy the battery and cause personal injury.

7. Keep the cables away from fans and belts.

NOTE: The operator must be in operator’s seat and have seat belt fastened.

8. Start the engine.

9. After engine has started, first remove the cable connected to the engine or loader.

10. Then remove cable from the loader battery positive terminal (+).

Damage to the alternator can occur if:

• Engine is operated with battery cables disconnected.

IMPORTANT

• Battery cables are connected •

when using a fast charger or when welding on the loader. (Remove both cables from the battery.)

Extra battery cables (booster cables) are connected wrong.

I–2023–1285

–6–1–

630, 631, 632 Loader Service Manual

ROPS ELECTRICAL SYSTEM (Harness P/N 6558859)

E–01188

–6–2–

630, 631, 632 Loader Service Manual

ROPS WIRING DIAGRAM (Harness P/N 6557492)

E–01191

–6–3–

630, 631, 632 Loader Service Manual

630 ENGINE ELECTRICAL SYSTEM (S/N 14999 & Below) (Harness P/N 6558862)

Coil

Starter

Battery

Solenoid

Flywheel Alternator

E–01179

–6–4–

630, 631, 632 Loader Service Manual

ENGINE WIRING DIAGRAM 630 (S/N 14999 & Below) (Harness P/N 6558862)

DIAGRAM E–01198

–6–5–

630, 631, 632 Loader Service Manual

ENGINE ELECTRICAL SYSTEM 631 (S/N 4997 12999 & Below)

Battery

Hydrostatic Temperature Switch

Alternator

Hydrostatic Pressure Switch

Starter

Pre–Heater Solenoid

Oil Pressure Switch

E–01187

–6–6–

630, 631, 632 Loader Service Manual

ENGINE WIRING DIAGRAM 631 (S/N 4997 12999 & Below)

E–01199

–6–7–

630, 631, 632 Loader Service Manual

ENGINE ELECTRICAL SYSTEM

Coil

Distributor Carburetor Valve Solenoid

Battery

Fuse On Earlier Models Only Starter

Alternator

Starter

E–01173R

–6–8–

630, 631, 632 Loader Service Manual

ENGINE WIRING DIAGRAM

E–01190

–6–9–

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–6–10–

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6–2 ELECTRICAL INFORMATION

GENERAL Regulator Rectifier

CAUTIONS to be taken in use of the alternator: 1. Do Not reverse the battery connections. This is a negative ground system only.

2. Connect booster batteries correctly – positive to positive and negative to negative.

3. Do Not polarize the alternator.

4. Do No ground any wires from the stator or modules which terminate at connectors.

Flywheel

Stator B–02958

5. Do Not operate the engine with the battery disconnected from the system.

Fig. 6–1

Flywheel Alternator System (630)

6. Disconnect at least one battery cable if a battery charger is used.

6–2.1 Troubleshooting The Flywheel Alternator (630) Before any electrical system tests are made, first check for broken wires or loose connections. Be sure that the modules are fastened tight to the engine. The regulator module must be in full contact with the metal surface for good ground connection.

The rectifier module must be insulated from the metal, but must be fastened tight for good heat removal.

–6–19–

630, 631, 632 Loader Service Manual

PROBLEM: BATTERY OVERCHARGE TEST

TEST RESULT

Test 1.0 With engine running at full RPM, check battery voltage W/DC voltmeter.

POSSIBLE CAUSE & REMEDY

1.1

If voltage is over 15.0.

1.1

Regulator not functioning properly. Replace module.

1.2

If voltage is under 15.0.

1.2

Alternator functioning properly.

Check battery condition.

With engine running at full RPM, check battery W/DC meter. If voltage is greater than 14 volts, put load on battery to reduce voltage below 14 volts.

1.1

If the charge rate increases–

1.1

Alternator functioning properly.

Battery was fully charged.

1.2

If the charge rate does not increase–

1.2

Proceed with Test 2.0.

Conditions and procedures

2–1

If the charge rate increases–

2.1

the same as Test 1.0 except the regulator module is disconnected.

Regulator was at fault. Replace the module.

2.2

If the charge rate does not increase–

2.2

Regulator is not a Continue with Test 3.0.

fault.

3.1

If the charge rate increases–

3.1

Rectifier module at Permanently install rectifier module.

fault. new

3.2

If the charge rate does not increase–

3.2

Continue with Test 4.0.

4.1

If one of the two voltages is zero or they are over 10% apart–

4.1

Te stator is faulty and must be replaced.

PROBLEM: LOW/NO CHARGE Test 1.0

Test 2.0

Test 3.0

Test 4.0

Test conditions and procedure the same as 1.0 except with new rectifier module plugged in.

With engine stopped, unplug all connectors between modules and stator. Start engine and run at 2400 RPM. With AC voltmeter check voltage between each of the black stator leads and ground.

6–2.2 To Check The Stator METER PROBE CONNECTIONS + (Red) – (Black) Black #1 Black #1 Black #2 Black #1 Black #2

Revised Mar. 85

to Black #2 to Eng. Gnd. to Eng. Gnd. to Red to Red

METER VALUE 0.40 ohm 0.02 ohm 0.02 ohm 3.20 ohms 2.80 ohms

–6–20–

REPLACE STATOR IF . . .

00 Indicates Open Circuit

630, 631, 632 Loader Service Manual

6–2.3 To Check the Rectifier Module Identification can be made of the rectifier module by the three wires and label. Use an ohmmeter to static check the circuit, as follows: (Engine stopped) METER PROBE CONNECTIONS + (Red) – (Black) White lead Black #1 White lead Black #2

NORMAL METER INDICATION

to Black #1 to White lead to Black #2 to White lead

No Continuity Continuity No Continuity Continuity

NOTE: Current flow must be in one direction only. If readings are not as indicated replace the module.

6–2.4 To Check the Regulator Module Identification can be made of the regulator module by the two wires (color black and red) leading to the connector.

Use an ohmmeter to static check the circuit, as follows: (Engine stopped) METER PROBE CONNECTIONS + (Red) – (Black) Red Eng. Gnd. Red Black Black Eng. Gnd.

to Eng. Gnd. to Red to Black to Red to Eng. Gnd. to Black

METER INDICATION (Good)

REPLACE MODULE If there is . . .

No Continuity

Continuity

No Continuity

Continuity

Continuity

No Continuity

6–3 ELECTRICAL CIRCUIT (631, 632) There are two basic circuits in the electrical system.

1. Charging circuit (alternator, regulator and battery).

2. Starting circuit (switch, solenoid, battery and starter).

NOTE: Disconnect battery ground cable before making any repairs to the electrical circuits.

In addition to the two basic circuits there is an accessories circuit which includes operating lights.

6–3.1 Electrical Troubleshooting The two most common problems with the electrical system are: 1. Battery has low charge.

2. Battery is being over–charged.

The charts give the correct sequence for finding problems and making repairs (See Page 6–22).

Revised Mar. 85

–6–21–

630, 631, 632 Loader Service Manual

CHART A BATTERY HAS LOW CHARGE CAUSE

CORRECTION

Alternator belt is loose or damaged.

Tighten or replace belt.

Battery connections are poor.

Tighten clean or replace battery connections.

Battery has defect.

Refillable Type: 1. Check electrolyte level, add water if necessary.

2. Check hydrometer.

electrolyte

with

Maintenance Free Type: 1. Check electrolyte ‘‘eye’’ if battery has one.

Electrical system has incorrect ground.

(Ammeter will show discharge).

1. Check insulation.

all

wires

for

broken

Alternator is not charging the battery.

1. Check the alternator for open diode at alternator connector wire.

CHART B BATTERY OVER–CHARGE

TEST With engine running at full RPM, check battery voltage/DC voltmeter.

TEST RESULT

POSSIBLE CAUSE & REMEDY

If voltage is over 15.0

Regulator not function– ing properly. Replace as needed.

If voltage is under 15.0

Alternator functioning properly. Check battery condition.

6–3.2 ROPS Electrical Connector Check the connector on the wiring harness for water in the connector or damaged by being over–tightening.

Put sealant (available from Clark Central Parts) on one half of the connector and then fasten the connector together. Do not force the connector together because it can be put together 180° out alignment. Do not use a tool to tighten the connector, hand tight only.

–6–22–

630, 631, 632 Loader Service Manual

6–3.3 ALTERNATOR ADJUSTMENT REPLACEMENT (631, 632)

BELT AND

1

Adjustment: 1. Remove belt shield.

2. Check for correct freeplay halfway between sheaves (Fig. 6–2 & Fig. 6–3) with 5 lbs. (2,27 kg) force.

1/2’’ (13 mm)

3. Loosen alternator bolts and move alternator for correct adjustment.

Replacement: 1. Loosen alternator adjustment bolts and move alternator to loosen belt.

C–02299

Fig. 6–2

Belt Tension Adjustment (631)

2. Remove belt.

1/2’’ Movement

3. Install new belt.

4. Move alternator to tighten belt for correct freeplay with 5 lbs. (2,27 kg) force half way between sheaves (Fig. 6–2 & Fig. 6–3).

1/4’’ Movement

5. After running engine for several hours, check belt tension and make adjustments as necessary.

Alternator

6–3.4 Check Condition of Battery and Cables 1. Check electrolyte level and add distilled water if necessary.

2. Check battery for voltage and amperage.

3. Check cables to be sure both are clean and tight.

B–02661

Fig. 6–3

Belt Tension Adjustment (632)

6–3.5 Check Alternator Wiring

No. 2 No. 1 Terminal Terminal

1. Turn the key switch on.

2. Connect a voltmeter between ground and (Fig. 6–4):

‘‘Bat’’ Terminal

a. No. 1 alternator connector b. No. 2 alternator connector c. ‘‘BAT’’ connector 3. If any of these tests show zero voltage, the wiring has a defect.

4. Find defect in wiring and make repair.

R Terminal Test Hole

5. Check voltage again.

B–02113

Fig. 6–4

Alternator

–6–23–

630, 631, 632 Loader Service Manual

6–3.6 Check Alternator Output

WARNING

Put jackstands under the front axles and rear corners of frame before running the engine for service.

Failure to use jackstands can allow the machine to fall or move and cause injury or death.

W–2017–0286

1. Disconnect negative battery cable.

2. Remove wire from ‘‘BAT’’ connector on alternator and fasten it to one connector of an ammeter. Fasten the other connector of the ammeter to the ‘‘BAT’’ connector of the alternator.

3. Connect battery cable again.

4. Remove coil wire and turn the engine with the starter for approximately 30 seconds to cause a discharge of the battery.

5. Install coil wire and start engine and run at full throttle. The ammeter reading must be within 10 amps. of rated amperage (marked on alternator case).

6. If reading is correct, alternator is good. If reading is more or less than 10 amps. of rated amperage, check the regulator.

6–3.7 Check Regulator 1. Connect ammeter as in paragraph 6–3.6.

2. Remove coil wire and turn engine with the starter for approximately 30 seconds to cause a discharge of the battery.

3. Install coil wire, start engine and run at full throttle.

4. Put a small screwdriver in test hole (Fig. 6–5).

5. If ammeter reading is within 10 amps. of rated amperge (marked on alternator case), the regulator probably has a defect./ If ammeter is not within 10 amps. of rated amperage, check the diode trio, rectifier, stator or rotor.

See below for thes checks.

6–4 ALTERNATOR SERVICE 6–4/1 Alternator Removal 1. Disconnect negative battery cables.

2. Disconnect wires from alternator.

3. Remove adjustment bracket bolt.

4. Remove two bolts that hold alternator and remove alternator.

6–4.2 Alternator Disassembly

Test Hole

1. Put a mark across each half of alternator case to help in correct assembly.

2. Remove sheave from shaft.

3. Remove four bolts that hold case together.

4. Use a screwdriver to move halves apart. Slide the rotor out of housing.

5. Remove nuts that hold the three stator wires to the housing. Remove the stator.

6. Disconnect the diode trio.

A–02211 B–02113

Fig. 6–5 –6–24–

Checking Regulator

630, 631, 632 Loader Service Manual

6–4.3 Checking Rotor (Fig. 6–6)

Check For Grounds

1. Connect an ohmmeter between one slip ring and shaft. There must be maximum resistance.

Check For Grounds

Check For Opens

2. Connect an ohmmeter between both slip rings. There must be 2.4 to 3.0 ohms. of resistance. If not, there is a defect in the rotor.

6–4.4 Checking Rotor (Fig. 6–6) Check For Shorts And Opens

1. Connect a test light between the center wire connection and one of the outside wire connections.

If the light does not come on, there is a defect in the stator.

A–01857

Fig. 6–6 Checking Rotor Coil Wires

Check For Opens

B–02108

Fig. 6–7 Checking Stator Coil Wires

2. Connect a test light between the center wire connection and the other outside connection. If the light does not (1) come on, there is a defect in the stator.

3. Connect the test light between one of the wire connections and the frame of the stator. If the light comes on, there is a defect in the stator.

6–4.5 Checking Diode Trio (Fig. 6–8) 1. Connect a D.C. test light between the single connection and one of the three connections. Connect the tester the opposite way. The light must come on when connected one way, but not when connected the other way.

A–02382

IMPORTANT

Do not use voltage which is more than circuit voltage to check the diode trio or the rectifier on the alternator.

Fig. 6–8 Checking Diode Trio

I–2026–0284

2. Do step (1) for the other two diodes.

3. Connect the test light between the center connection and each outside connection (one at a time). If the light comes on, there is a defect in the diode trio.

6–4.6 Checking Rectifier (Fig. 6–9) 1. Remove rectifier from alternator.

Insulated Heat Sink

2. Tighten three nuts on the connections.

3. Connect test light between one connection and the insulated heatsink.

Connect the tester the opposite way. The light must come on when connected one way, but not when connected the other way.

4. Connect the test light between the same connection and the grounded heatsink. Connect the tester the opposite way. The light must come on when connected one way but not when connected the other way.

5. Do steps (3) and (4) on both of the other connections. If any of the tests are bad, make replacement of rectifier.

Grounded Heat Sink

B–02101 B–02102

Fig. 6–9 Checking Rectifier –6–25–

630, 631, 632 Loader Service Manual

6–4.7 Alternator Assembly and Installation

Insulated Washers

Assembly and installation is reverse of removal and disassembly.

If the regulator is removed, be sure the two insulation washers and spacers are in good condition (Fig. 6–10).

To install the rotor, put a piece of straight wire through the housing to hold the brushes in place (Fig. 6–11).

6–5 STARTER 6–5.1 Checking Starter 1. Lift the Bobcat and put blocks under the frame so that there is no danger of the machine falling and causing personal injury.

B–02128

Fig. 6–10 Insulation Washers & Spacers

2. Keep ignition switch off. Be sure the battery has full charge and the connections are clean and tight.

3. Connect a jumper wire between the small connection on solenoid and the battery connection on solenoid (Fig. 6–12). If the starter turns, but does not turn the engine, the defect is in the starter drive. If the starter does not turn, continue with step below.

4. Connect the jumper wire between the battery connection on solenoid to the lower connection on starter (Fig. 6–13). If the starter turns rapidly, the defect is in the solenoid. If starter does not turn, the defect is in the starter.

6–5.2 Removing Starter 1. Disconnect negative battery cable.

B–02097

2. Disconnect wires from starter connections.

Fig. 6–11 Holding Brushes

3. Remove the two bolts that hold the starter is place, and remove starter.

Jumper Wire 6–5.3 Starter Disassembly (Fig. 6–14) 1. Remove the connector link between the solenoid and the starter.

Bat S M

2. Remove nuts and washers that fasten the solenoid to the drive end of housing.

3. Remove the main part of the solenoid (Item 7). Remove the rubber seal (Item 14), plunger and spring assembly (Item 8) by lifting it from the top of the shift fork (Item 9).

Cranking Motor

NOTE: The plunger (Item 8) must also be replaced if the main part of the solenoid is replaced.

4. Remove rubber sealing block from between the drive end housing and the frame.

5. Remove the retaining clip (Item 18) from the groove in the shift fork pivot pin and remove the pin (Item 17).

6. Remove nuts and drive housing (Item 21) from starter frame (Item 25).

7. Remove the shift fork (Item 9) from the starter frame.

8. Remove dust cover (Item 33), cotter pin (Item 32), shim washer (Item 31) and thrust plate (Item 30) from armature shaft at commutator end. Remove the armature (Item 26), complete with internal thrustwasher (Item 27) and drive assembly (Item 24), through the drive end of starter frame.

A–01991

*Fig. 6–12 Checking Solenoid

Jumper Wire Solenoid Bat S M

Pin

Cranking Motor

9. Remove thrustwasher (Item 27) from the commutator end of armature shaft.

A–01992

Fig. 6–13 Checking Starter –6–26–

630, 631, 632 Loader Service Manual

PI–02236

Fig. 6–14

Starter Assembly

10. Remove drive stop ring (Item 22), thrust collar (Item 23) and slide the drive assembly off the armature shaft.

11. Remove two screws (Item 28) from end plate (Item 2) and remove end plate from starter frame.

6–5.4 Starter Cleaning and Inspection NOTE: DO NOT use solvent to clean the drive because solvent will remove lubricant and cause the drive to slip.

1. Use a brush and compressed air to clean the drive, field coils, armature, commutator, front plate and rear housing. Wash all other parts in solvent and let dry.

2. Inspect the armature for broken or burned insulation and loose connections.

3. Check armature for open and ground circuits.

4. Check armature shaft and bearings for damage and wear. If commutator is rough, make smooth.

5. Check brush holders for broken springs and for broken insulation. Make replacement of the brushes if wear is more than 5/16 inch (8.0 mm).

6. Check brush spring tension. Make replacement if springs are weak.

7. Inspect field coils for burned or broken insulation and electrical continuity.

Check field brush connections and wire insulation. A brush kit is available.

8. Check starter drive gear for tooth wear. The starter drive gear must engage more than 1/2depth of ring gear teeth on flywheel.

–6–27–

630, 631, 632 Loader Service Manual

6–5.5 Brush Replacement 1. Cut the two brush wires at the connection post. Use a file or hacksaw to make a groove in the top of the post deep enough to hold new brush wires. Be sure the insulation is on the new brush wires. Solder the brush wires into the groove.

2. Cut the other brush wires about 1/4 inch (6,3 mm) from the joint of the field winding. Solder the new brush wires to the ends of the original brush wires.

Be sure insulation is over solder connections.

6–5.6 Starter Assembly 1. Put a small amount of lubricant on the armature shaft splines. Install the drive assembly on armature shaft, install the thrust collar and stop ring.

2. Install thrustwasher (Item 30) on commutator end of armature shaft.

3. Install brushes in end plate and fasten end plate to starter frame with screws.

4. Put a small amount of lubricant on the internal thrustwasher (Item 27) and install the armature and drive assembly through the drive end of starter frame. Install thrust plate, shim washer and cotter pin on armature shaft.

Check the end play of the armature. Add or remove shims for correct end play. Install the dust cover.

Terminal Covers Fig. 6–15

C–02448

Starter Solenoid

5. Install rubber seal, plunger and return spring assembly on the top of shift fork. Put the shift fork on the drive assembly.

6. Install the drive housing on starter frame and install washers and nuts.

7. Put the pivot pin into housing and shift fork and install clip.

8. Install rubber sealing block between drive housing and frame.

9. Put main part of solenoid over plunger assembly and into drive housing.

Install washers and nuts.

10. Install link between solenoid and starter.

NOTE: On the 632 loader install a terminal cover (P/N 656012) at the starter solenoid (Fig. 6–15) to prevent a possible ground at the terminal.

6–5.7 Check Electrical Wiring 1. Check all wires for broken insulation and replace and bad wires.

2. The electrical connector (between the ROPS and Main Frame) can get corrosion. Put a sealant (water) resistant on the connector before installing (See the Parts Manual or Microfiche for the part number of the sealant).

–6–28–

630, 631, 632 Loader Service Manual

ENGINE SERVICE Paragraph Number DUET ENGINE (631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FORD ENGINE (632) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WISCONSIN (630) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B 7C 7A

Page Number 7B–1 7C–1 7A–1

ENGINE SERVICE

WISCONSIN (630)

DEUTZ (631)

FORD (632)

–7A––3–

630, 631, 632 Loader Service Manual

–7A––2–

630, 631, 632 Loader Service Manual

ENGINE SERVICE (WISCONSIN ENGINE–630) Paragraph Number

Page Number

ACCESSORIES INSTALLATION . . . . . . . . . . . . . . . . . . . .

ACCESSORIES REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .

AIR HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . .

AIR HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . .

7A–37 7A–5 7A–35 7A–7

7A–11 7A–4 7A–11 7A–4

CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .

CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAMSHAFT GEAR INSTALLATION . . . . . . . . . . . . . . . . .

CAMSHAFT GEAR RMOVAL . . . . . . . . . . . . . . . . . . . . . . .

7A–22 7A–19 7A–31 7A–11

7A–7 7A–7 7A–10 7A–4

CARBURETOR & MANIFOLD INSTALLATION . . . . . . . .

CARBURETOR & MANIFOLD REMOVAL . . . . . . . . . . . .

CARBURETOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . .

7A–34 7A–8 7A–3

7A–11 7A–4 7A–3

CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .

7A–23 7A–18

7A–7 7A–7

CYLINDER BLOCK INSTALLATION . . . . . . . . . . . . . . . . .

CYLINDER BLOCK REMOVAL . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . .

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . .

7A–24 7A–17 7A–33 7A–9

7A–8 7A–6 7A–10 7A–4

ENGINE IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . .

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7A–2 7A–4

7A–2 7A–3

FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .

FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7A–36 7A–6

7A–11 7A–4

GEAR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . .

GEAR COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . .

GOVERNOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7A–32 7A–10 7A–38

7A–10 7A–4 7A–11

IDLER GEAR & SHAFT INSTALLATION . . . . . . . . . . . . .

IDLER GEAR & SHAFT REMOVAL . . . . . . . . . . . . . . . . . .

7A–30 7A–12

7A–10 7A–5

OIL PAN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PAN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7S–29 7A–13 7A–28 7A–14

7A–9 7A–5 7A–9 7A–5

PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . .

PISTONS & CONNECTING ROD INSTALLATION . . . . .

PISTONS & CONNECTING ROD REMOVAL . . . . . . . . .

7A–25 7A–27 7A–15

7A–8 7A–8 7A–5

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7A–1

7A–1

VALVE TAPPET INSTALLATION . . . . . . . . . . . . . . . . . . . .

VALVE TAPPET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .

VALVES AND SEAT INSERT INSTALLATION . . . . . . . . .

VALVES AND SEAT INSERT REMOVAL . . . . . . . . . . . . .

7A–21 7A–20 7A–26 7A–16

7A–7 7A–7 7A–8 7A–6

–7A––1–

WISCONSIN (630)

630, 631, 632 Loader Service Manual

–7A–0–

630, 631, 632 Loader Service Manual

7A ENGINE SERVICE (WISCONSIN ENGINE – 630) 7A–1 TROUBLESHOOTING PROBLEM Engine will not turn with starter.

Engine turns with starter, but is difficult to start.

Engine has little power or runs rough.

Engine overheats.

CAUSE

CORRECTION

Battery charge low.

Increase charge in battery, find cause for charge loss.

Cables loose or dirty.

Clean and tighten cables.

Starter defect, solenoid or wiring.

Check starting circuit. Make repairs as needed.

Wrong starting procedure.

See Owner’s Manual for correct procedure.

No fuel in tank.

Add fuel, if needed.

Vent in fuel filter cap has restriction.

Clean as needed.

Broken wire to fuel shut–off solenoid.

Make repairs as needed.

Dirt or water in fuel system.

Make repairs as needed.

Defect in carburetor or fuel pump.

Make repairs as needed.

Hole in fuel line.

Make repairs as needed.

Choke not closing completely.

Make adjustment of linkage.

Ignition system has defect.

Check and make repairs as needed.

Wrong oil in engine.

See Oil Specifications.

Engine has lost compression.

Overhaul the engine.

Engine has overheated.

Clean cooling system, check ignition.

Defect in ignition system.

Make repairs as needed.

Dirt or water in fuel system.

Clean and make rpairs as needed.

Defect in fuel pump.

Check and make repairs as needed.

Governor adjustment is wrong.

Check and needed.

Dirty air cleaner.

Check air cleaner.

Engine has lost compression.

Overhaul the engine.

Cooling system is dirty.

Clean cooling system.

Engine air housing cover damaged or missing.

Check air housing covers.

Ignition system set wrong. Engine is overloaded.

Check ignition timing, Operate loader with engine at full throttle.

–7A–1–

make

adjustment

if

630, 631, 632 Loader Service Manual

7A–2 ENGINE IGNITION SYSTEM 7A–2.1 Distributor Maintenance

‘‘X’’

See Section 8 ‘‘Technical Data’’ for point gap specification. To make adjustment of point gap: 1. Turn the engine by hand until the point block is on a high point of the cam.

Timing Sight Hole

2. Loosen the stationary contact nut and move the contact in or out, until gap is correct.

3. Tighten the nut and check the gap again.

The distributor must have regular lubrication and inspection made for conditions which can effect its Fig. 7A–1 Timing Marks operation. After every 50 hours of operation, the oil cup on the side of the distributor base must have 3 to 5 drops of medium engine oil. Every 100 hours, apply 3 to 5 drops of medium oil to the top of the cam sleeve. Do not put a large amount of oil in the distributor.

B–02975

7A–2.2 Timing Procedure Find the timing ‘‘x’’ mark on the flywheel vane, in line with the large ‘‘DC’’ letters near the center of the flywheel (Fig. 7A–1). Put white chalk or paint on the ‘‘x’’ marked vane.

To check timing: 1. Connect timing light to number one spark plug.

2. Start engine and run at over 1800 RPM. 3. Point timing light at the timing sight hole (Fig. 7A–1).

4. The engine must be timed at 23 before dead center. Check to see that the ‘‘x’’ marked vane is in line with the timing sight hole in the flywheel housing (Fig. 7A–1).

WARNING

If the engine is running below 1800 RPM when checking timing, the automatic adjustment in the distributor will not be fully forward.

Wrong timing can cause permanent damage to the engine.

W–

Distributor A–01836

Fig. 7A–2 Loosening Clamp For Advance Arm

5. To adjust timing, loosen the distributor clamp screw and turn the distributor body until timing is correct (Fig. 7A–2).

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

7A–2.3 Spark Plugs

Spark Plug

See Section 8 ‘‘Technical Data’’ for spark plug gap specification. Spark plugs must be kept clean (Fig. 7A–3). If the insulation is cracked, replace the spark plug. The spark plug thread is 18 millimeter. Be sure to use a good gasket under the spark plug.

A–01825

Fig. 7A–3 Setting Spark Plug Gap –7A–2–

630, 631, 632 Loader Service Manual

7A–3 CARBURETOR SERVICE (Fig. 7A–4) Adjustments 1. Adjust the throttle stop screw for correct maximum RPM by turning the screw IN to increase RPM and OUT to decrease RPM.

Idler Adjustment Needle

Throttle Stop Screw

2. Adjust the idle adjustment needle for smooth idle of the engine. Turn the needle OUT for more fuel and IN for less fuel.

7A–3.1 Float Adjustment To check the position of the float assembly, remove the fuel bowl from the throttle body by removing the three screws.

1. Use a depth gauge to measure from the machined edge (no gasket) of float bowl to the top side of the float body (highest point). This measurement must be 31/32’’ (24,61 mm) plus or minus 1/32’’ (,79 mm).

2. To increase or decrease the distance between the float body and the machined edge, use a long nosed plier to bend the lever close to the float body.

NOTE: Too much fuel to the engine can be caused by the float level being too high. Make adjustment of float level. It may be necessary to change the float level adjustment to 1–1/4” (31, 75 mm). This is a recommendation for operation in rough ground.

7A–3.2 Governor Adjustment The control rod between the governor and the carburetor must be the correct length for the governor to operate correctly.

1. Stop the engine.

2. Disconnect the control rod from the governor linkage.

3. Push the governor linkage as shown in figure 7A–5.

4. Push the control rod toward the carburetor (Fig. 7A–5).

C–02319

Fig. 7A–4

Carburetor

5. Make adjustment of the control rod until it just goes into the hole in the governor linkage. Then turn the rod IN (shorter) TWO MORE TURNS. 6. Install the control rod into the hole in the governor linkage and install the cotter pin.

Push Control Rod

Governor Linkage

7. There must be about 1/16 inch (1.59 mm) clearance between the stop pin and the throttle stop screw (Fig. 7A–6).

8. The governor linkage has 12 holes for installing the governor spring (Fig. 7A–7).

9. Install the spring in hole number 10.

Control Rod

10. Connect a tachometer to the engine. Start engine and run at full throttle.

Push Linkage

11. Adjust the screw at the bottom end of the governor spring until you get correct IDLE (Maximum) (See 8A TECHNICAL DATA for correct idle speed).

7A–4 REMOVAL OF ENGINE

B–02575

Fig. 7A–5 Governor Adjustment

1. Remove the ROPS (Operator Guard).

2. Remove the exhaust pipe.

3. Disconnect the throttle and choke linkages.

4. Disconnect the fuel line and air cleaner hose.

1/16 inch

5. Disconnect the wiring at connector plug.

6. Remove the engine oil filter.

7. Remove the battery cables.

8. Remove the fastening bolts from the support plate for the engine.

9. Use a hoist to lift the engine. Slide the engine backward until the drive coupling is disconnected from the transmission.

10. Lift the engine out through the rear of the Bobcat.

B–03137

11. To install, reverse the above steps.

Fig. 7A–6 –7A–3–

Linkage Adjustment

630, 631, 632 Loader Service Manual

7A–5 REMOVAL OF ACCESSORIES Nut

Remove the engine oil filter, starter and other installed parts.

12 10 8 6 4 2

7A–6 REMOVAL OF FLYWHEEL 1. Remove the flywheel nut and washer (Fig. 7A–8).

2. Pull the flywheel off of the taper on crankshaft. (Use a soft hammer to loosen the flywheel (Fig. 7A–9).

7A–7 REMOVAL OF AIR HOUSING (FIG. 7A–10) 1. Remove covers.

the

cylinder

Washer

A–01833

Fig. 7A–7 Governor Linkage

B–02584

Fig. 7A–8

Remove Flywheel Nut

head

2. Remove the bolts holding flywheel housing to the lower cylinder housing.

3. Remove the bolts holding the flywheel housing to the gear cover.

7A–8 REMOVAL OF CARBURETOR AND MANIFOLD

Flywheel

1. Remove the manifold nuts.

2. Lift off the manifold section (Fig. 7A–11).

7A–9 REMOVAL OF CYLINDER HEADS

A–01823

Fig. 7A–9 Loosening Flywheel

Cylinder Head Covers Flywheel Shroud

A–01841

Fig. 7A–10 Removing Air Housing

Manifold

1. Remove head bolts.

2. Lift the heads from the engine (Fig. 7A–12).

NOTE: Bolts are of different lengths and must be installed according to the bosses on the heads.

7A–10 REMOVAL OF CYLINDER HEADS A–01830

1. Disconnect the governor linkage.

Fig. 7A–11 Remove Manifold

B–02590

Fig. 7A–12 Removing Cylinder Heads

2. Remove the gear cover bolts.

3. Drive out the two dowel pins (Fig. 7A–13).

Dowel Pin

4. Remove the cover.

7A–11 REMOVAL OF CAMSHAFT 1. Remove the three bolts and lock washers (Fig. 7A–14).

2. Pull the gear from the shaft.

NOTE: The camshaft gear has an offset hole to aid in assembly.

A–01838

Fig. 7A–13 Remove Dowel Pins –7A–4–

A–01824

Fig. 7A–14 Remove Camshaft 630, 631, 632 Loader Service Manual

7A–12 REMOVAL OF IDLER GEAR AND SHAFT 1. Remove the allen set screw (Fig. 7A–15).

2. Remove the idler gear and shaft using a gear puller (Fig. 7A–15).

7A–13 REMOVAL OF OIL PAN 1. Turn the engine so that oil pan is on top (Fig. 7A–16).

2. Remove the oil pan bolts and remove the oil pan (Fig. 7A–16).

A–01842

7A–14 REMOVAL OF OIL PUMP

Fig. 7A–15

Remove Idler Gear

1. Remove the lock nut and pump drive gear from shaft.

2. Remove the grooved pipe plug from bottom of oil pan (Fig. 7A–17).

3. Use a 5/32 allen wrench to remove the lock nut from the pipe plug hole (Fig. 7A–17).

4. Remove the oil pump.

7A–15 REMOVAL OF PISTONS AND CONNECTING RODS 1. Use a 1/2’’ socket wrench to loosen and remove hex nuts from the connecting rods.

2. Hit the ends of the bolts lightly to release the connecting rod cap (Fig. 7A–18).

3. Remove carbon that can interfere with removal of pistons from the upper end of the cylinders (Fig. 7A–19).

A–01834

Fig. 7A–16 Remove Oil Pan

A–01831

Fig. 7A–17 Remove Oil Pmmp

Connecting Rod Cap

4. Turn the crankshaft until the piston is at the top of its stroke.

B–02582

B–02581

Fig. 7A–18 Remove Connecting Rod Caps

Fig. 7A–19 Remove Carbon From Cylinder Wall

–7A–5–

630, 631, 632 Loader Service Manual

5. Push the connecting rod and piston assembly upward and out through the top of the cylinder (Fig. 7A–20).

6. Put cap back on connecting rod to keep them together.

7A–16 REMOVAL OF VALVE AND SEAT INSERTS 1. Remove the valve tappet inspection plate and push the valve spring together with an automotive valve lifting tool (Fig. 7A–21).

2. Put a rag into the opening at the bottom of the valve chamber so the holding locks do not fall into the engine oil pan.

Piston Assembly

B–02585

Fig. 7A–20

Remove Rod & Piston

3. Remove the holding locks, seats, springs, valves and clean them in solvent.

NOTE: Mark valves so that they will be put in the same guide during assembly as they were when removed.

4. Remove the inlet and exhaust valve inserts when badly worn (See Paragraph 7A–26).

5. Inspect the valve guides for wear and remove when the valve stem clearance is more than .006 inch (,152 mm) (Fig. 7A–22). Use a driver to push out the old guides.

7A–17 REMOVAL OF CYLINDER BLOCK 1. Remove the six nuts which hold each cylinder block (Fig. 7A–23).

A–01827

Fig. 7A–21 Remove Valves

A–02543

Fig. 7A–22 Checking Valve Guides

2. Lift off the cylinder blocks.

B–02588

Fig. 7A–23 Remove Cylinder Block Nuts –7A–6–

630, 631, 632 Loader Service Manual

7A–18 REMOVAL CRANKSHAFT

OF

Crankshaft

1. Remove the six bolts in the main bearing plate and remove the plate (Fig. 7A–24).

Main Bearing Plate

2. Pull the crankshaft from the end of the housing (Fig. 7A–24).

7A–19 REMOVAL OF CAMSHAFT 1. Pull the camshaft from the flywheel end of the engine (Fig. 7A–25).

7A–20 REMOVAL TAPPETS

OF

VALVE

A–01843

Fig. 7A–24

Remove Crankshaft

1. After the camshaft has been taken out, remove the valve tappets (Fig. 7A–25).

7A–21 INSTALLATION OF VALVE TAPPETS 1. Install the valve tappets into correct position before the camshaft is installed (Fig. 7A–25).

NOTE: Valve tappet adjustment is made after cylinder blocks have been installed. Correct clearance is .008’’ (0,2 mm) for the inlet and .016 (0,4 mm) for the exhaust valves.

7A–22 INSTALLATION OF CAMSHAFT 1. Install the spring and plunger at the end of the camshaft.

2. Push the camshaft in thru the flywheel end of the engine (Fig. 7A–25).

A–01846

Fig. 7A–25

Installing Camshaft

Fig. 7A–26

Crankshaft (3 Bearings) Seal

7A–23 INSTALLATION OF CRANKSHAFT 1. Put the crankshaft in thru the end of the housing (Fig. 7A–24).

2. Install the main bearing plate using the same quantity and thickness gaskets and shims as when removed. End play must be .002’’ to .004’’ (0,05 to 0,10 mm) when the engine is cold.

NOTE: The main bearing plate cannot be installed wrong. The mounting holes are offset so that the plate is correct for bearing lubrication.

3. Install the six bolts in the main bearing plate and tighten to 25–30 ft.–lbs.

(34–41 Nm) torque.

B–02306

7A–23a Three Bearing Crankshaft 1. Crankshaft seal (Fig. 7A–26) must be installed so the end of the seal is even with the end of the bearing support.

2. Put LOCTITE on the inside diameter of the bearing race before installing the race.

3. When installing the third bearing, push on the number side of the bearing until it is even with the inside of the bearing support (Fig. 7A–27).

Push Number Side of Bearing Until Even With Support

4. If a new bearing support is installed, crankshaft end play must be checked.

If end play adjustment is necessary, add or remove gaskets from the front bearing plate of the engine.

B–02307

Fig. 7A–27 Bearing Location (3 Bearings) –7A–7–

630, 631, 632 Loader Service Manual

7A–24 INSTALLATION CYLINDER BLOCKS

OF

Cylinder Block

1. Install the cylinder blocks and fasten each with six nuts (Fig. 7A–28).

2. Tighten nuts to 40 to 50 ft.–lbs.

(54–68 Nm) torque.

7A–25 INSTALLATION OF PISTON RINGS 1. Put the open end of the piston ring on first and spread to fit in groove (Fig. 7A–29).

2. There are four rings to each piston. The 4th (bottom) ring is the oil ring, the 3rd is the scraper ring, the 2nd ring is the compression ring and the 1st ring is the compression ring (See Fig. 7A–30).

B–02588

Fig. 7A–28 Install Cylinder Block

A–01826

Fig. 7A–29 Install Piston Rings

Compression Ring

3. Install the scraper ring with the scraper edge down (Fig. 7A–30).

7A–26 INSTALLATION OF VALVES AND SEAT INSERTS 1. Inspect all valve inserts and install new inserts when necessary.

Scraper Ring Oil Ring

2. Install each valve into the same guide from which each was removed.

3. Install the seat and spring and fasten with the valve locks (Fig. 7A–31).

4. Make adjustment of the valve tappet clearance (See Section 8 ‘‘Technical Data’’ for valve tappet clearance).

A–01844

Fig. 7A–30

Piston Ring Sequence

A–01827

Fig. 7A–31

Install Valves

5. Install the inspection plate for the valve tappets.

7A–27 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 the connecting rods when installed in the engine. Be sure that the hole in the cap is facing toward the oil spray nozzle (Fig. 7A–32). Install new nuts on the connecting rod bolts and tighten them to 20–28 ft.–lbs. (27–38 Nm) torque.

1. Install the piston and connecting rod assembly in the same bore as when removed.

Oil Hole NOTE: Put oil on the pistons, rings, piston pins, rod bearings and cylinder walls before assembly.

Oil Spray Nozzle Fig. 7A–32 –7A–8–

A–01859

Install Rod Caps

630, 631, 632 Loader Service Manual

2. Use a ring compressor and check that the ring gaps are 90 degrees apart, around the piston (Fig. 7A–33).

3. On engine with 4–ring pistons, check that the wide sections of the piston skirt are toward the maximum thrust side (Opposite the crankshaft rotation) (Fig. 7A–34).

4. Install the connecting rod cap with the bearing half installed (Fig. 7A–32).

B–02586

Fig. 7A–23 Install Pistons

5. Install the rod bearing nuts and tighten them to 20–28 ft.–lbs.

(27–38 Nm) torque.

7A–28 PUMP

INSTALLATION

OF

OIL

1. Install the oil pump into the crankshaft housing (Fig. 7A–35).

Be sure that the seat for the lock screw is in line with the hole for the screw in the crankshaft housing.

NOTE: See Page 7A–14 for complete Engine Oil Flow Circuit.

2. Install the lock screw into the pipe plug hole (Fig. 7A–36). Use a 5/32’’ Allen wrench to tighten the lock screw.

Crankshaft Rotation

3. Install the grooved pipe plug from the bottom of the housing (Fig. 7A–36).

Wide Skirt This Side

Wide Skirt This Side

7A–29 OIL PAN INSTALLATION 1. Install the oil pan and install the bolts. Tighten the bolts to 6–9 ft.–lbs. (8–12 Nm) torque.

C–01660

Fig. 7A–34 Connect Piston Installation (4–Ring Pistons Only)

B–02580

Fig. 7A–35

Install Oil Pump

–7A–9–

A–01831

Fig. 7A–36 Fasten Oil Pump 630, 631, 632 Loader Service Manual

7A–30 INSTALLATION OF IDLER GEAR AND SHAFT 1. Install the idler gear and shaft (Fig. 7A - 37).

2. Install the allen set screw (Fig. 7A - 38).

NOTE: Check that the oil groove and shaft is in the up position, and that the clearance between the idler gear and the shoulder of the shaft is .003–.004’’ (,08–,1 mm).

B–02574

Fig. 7A–37 Install Gear & Shaft

B–02576

Fig. 7A–38 Install Set Screw

7A–31 INSTALLATION OF GEAR COVER 1. Put the camshaft gear on the shaft so that the holes are in correct alignment (Figl 7A–39).

NOTE: Be sure that the spring, plunger and thrust button are in corret position (Fig. 7A–40).

2. Install the three bolts and lock washers (Fig. 7A–39).

7A–32 INSTALLATION OF GEAR COVER

B–02393

Fig. 7A–39 Installing Gear & Camshaft

1. Install the gear cover.

2. Install the gear cover bolts and two dowel pins. Tighten the bolts to 14–18 ft.–lbs. (19–24 Nm) torque (Fig. 7A–41).

Gear

3. Connect the governor linkage rod.

7A–33 INSTALLATION CYLINDER HEAD

OF Plunger

1. Install the cylinder heads.

2. Install the head bolts, using bolts by length, according to the bosses on the cylinder heads (Fig. 7A–42).

Spring C–01565

Fig. 7A–40 Installing Spring, Plunger & Gear

NOTE: Put oil on all of the cylinder head bolts to protect them from rust.

10

11 12

1

9

22

13

3. Tighten the head bolts in the sequence shown in figure 7A–42.

8 21

14

7 2

4. Tighten the cylinder head bolts to 22–24 ft.–lbs. (30–33 Nm) torque.

15 3 16 B–02578

Fig. 7A–41 Install Cover –7A–10–

6 4 5 17 18

2 19 B–02577

Fig. 7A–42 Install Cylinder Head 630, 631, 632 Loader Service Manual

7A–34 INSTALLATION OF CARBURETOR AND MANIFOLD ASSEMBLY 1. Install the manifold assembly on engine (Fig. 7A–43).

2. Install the manifold nuts and tighten them to 14–18 ft.–lbs.

(19–24 Nm) torque.

7A–35 INSTALLATION HOUSING

OF

AIR

1. Install the bolts for holding the flywheel housing to the gear cover.

2. Install the bolts for holding the flywheel housing to the lower cylinder covers (Fig. 7A–44).

A–01830

Fig. 7A–43 Install Manifold

3. Install the cylinder head covers (Fig. 7A–44).

7A–36 INSTALLATION FLYWHEEL

OF

1. Push flywheel on to the taper of the crankshaft. Check that the woodruff key is in position on the shaft and is in alignment with the groove in the flywheel bore.

2. Install the flywheel nut and washer (Fig. 7A–45).

7A–37 INSTALLATION ACCESSORIES

OF

Install the engine oil fiter, starter and other parts removed during assembly.

A–01841

7A–38 GOVERNOR SERVICE Fig. 7A–44 Install Cylinder Head Cover Governor failures, and noisy governors when engine is at idle speed are caused by the weights hitting the governor housing. Remove and disassemble the governor; then grind metal (at four places) from the two weights as shown in figure 7A–46.

Grind flush with taper on the weights.

Be sure to check the pivot points for wear.

Grind Corners Flush With Taper

NOTE: Be sure to adjust governor when you install it again (See Section 7A–3.2 Page 7A–5).

B–02584

Fig. 7A–45 Install Washer & Nut –7A–11–

A–02629

Fig. 7A–46 Governor Weights 630, 631, 632 Loader Service Manual

–7A–12–

630, 631, 632 Loader Service Manual

631 ENGINE SERVICE (DEUTZ ENGINE–FL411D) Paragraph Number

Page Number

BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B–6

7B–8

CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD & VALVES . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER, PISTONS, CONNECTING RODS . . . . . . . .

7B–12 7B–7 7B–8

7B–17 7B–8 7B–12

ENGINE FRONT COVER . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B–10 7B–4 7B–5

7B–14 7B–7 7B–7

FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL INJECTION NOZZLES . . . . . . . . . . . . . . . . . . . . . . .

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B–13 7B–3 7B–1

7B–19 7B–7 7B–3

GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B–11

7B–16

OIL PUMP, FILTER HOUSING AND RELIEF VALVE . . .

7B–9

7B–13

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B–1

7B–1

631 ENGINE SERVICE (DEUTZ ENGINE–F2L511) Paragraph Number

Page Number

BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B–20

7B–27

CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAMSHAFT. CYLINDER HEAD & VALVE . . . . . . . . . . . .

CYLINDER, PISTONS, CONNECTING RODS . . . . . . . .

7B–26 7B–21 7B–22

7B–38 7B–28 7B–22

ENGINE FRONT COVER . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B–24 7B–18 7B–19

7B–34 7B–27 7B–27

FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL INJECTION NOZZLES . . . . . . . . . . . . . . . . . . . . . . .

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B–27 7B–17 7B–16

7B–40 7B–26 7B–21

GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B–25

7B–37

OIL PUMP, FILTER HOUSING AND RELIEF VALVE . . .

7B–23

7B–34

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7B–14

7B–20

DEUTZ (631)

(Deutz F2L411D) –7B––1–

630, 631, 632 Loader Service Manual

(Deutz F2L411D) –7B–0–

630, 631, 632 Loader Service Manual

7B ENGINE SERVICE (DEUTZ–F2L411D – 631) 7B–1 TROUBLESHOOTING PROBLEM Engine will not turn over with starter.

CAUSE Battery has lost its charge.

Charge battery. Check the functions of charging system.

Loose battery connection.

Clean battery connections and cables.

Tighten the clamps.

Loose start connections.

Tighten the connections.

Defect in starter switch.

Make replacement of switch.

Broken or harness.

Engine fails to start or is difficult to start.

Engine misses, runs irregularly or stops.

CORRECTION

disconnected

wiring

Connect or make replacement of wiring.

Defective starter or solenoid.

Repairs as needed.

Wrong starting procedure.

Refer to ‘‘Starting Procedure’’ in the Bobcat Operator’s Manual.

No fuel in the tank.

Add fuel. Remove air from fuel system.

Air cleaner is dirty.

Service the air cleaner.

Fuel tank vent in cap as restriction.

Remove the cap and clean vent.

Fuel line has air leak or dirt, or water.

Correct as required.

Damaged fuel lift pump.

Make replacement of pump if needed.

Excess fuel assembly not working.

Check alignment and linkage.

Hydraulic–hydrostatic load on engine.

Place all controls in neutral and warm oil reservoir during very low temperatures.

Defect in fuel injection system.

Check and make repairs as needed.

Crankcase oil is thick.

Use engine oil of correct viscosity.

(See Oil Specification Chart).

Fuel injection set wrong.

Check timing.

Dirty fuel mixture, or restriction in fuel filter or vent.

Clean as required.

Poor compression.

Check for loose cylinder head screws.

Water in the fuel.

Make replacement of fuel.

(Deutz F2L411D) –7B–1–

630, 631, 632 Loader Service Manual

PROBLEM Engine overheats.

Too much engine vibration.

CAUSE

CORRECTION

Engine is overloaded.

Operate in low range. Operate at rated RPM.

Engine cooling fins are dirty.

Remove covers and clean cooling fins.

Engine has been operated with part of covers removed.

Clean cooling fins and install the covers.

Dirty engine oil.

Make replacement of engine oil.

Exhaust system has restriction.

Correct as necessary.

Injection timing is wrong.

Check fuel injection.

Loose engine mount. Worn rubber mounts.

Tighten bolts to correct Replace rubber mounts.

torque.

7B–1.1 Engine Mounts 1. Lubricate (with soap and water) the outside of the rubber mounts (Fig. 7B–1, Item 1) and install them into the engine mounts.

2. Install the front mount on the engine. Use a liquid adhesive (”Loctite”) on the bolts. Tighten the three bolts (Fig. 7B–1, Item 2) to 90–100 ft.–lbs. (125–135 Nm) torque.

3. Install the rear mount on the engine. Use a liquid adhesive (”Loctite”) on the bolts. Tighten the four bolts (Fig. 7B–1, Item 3) with your hand only.

5 Rear Mount

Front Mount

1 3

2 4

4. Install the engine into the loader.

5. Move the engine to align the universal joint between the engine and the hydrostatic pump.

1 E–1186R

Fig. 7B–1

Rubber Mounts

6. Put washers on the two bolts that go into the rear mount of the engine.

7. Install all four bolts (Fig. 7B–1, Item 4) through the bottom of the engine compartment and into the engine mounts. Put the washers (Fig. 7B–1, Item 5) and nuts on the bolts but do not tighten them yet.

1 Key Stock

8. Check the alignment of the universal joint as follows: (a) Remove the seat and seat pan. (b) Put a short piece of straight, flat material (key stock) against the flat surfaces (side and top) of the universal joint (Fig. 7B–2). (c) Move the engine so that it is in alignment within .25 inch (6,35 mm) (Fig. 7B–2, Item 1).

9. Tighten the four bolts (Fig. 7B–1, Item 3) on the rear mount of the engine to 65–70 ft.–lbs. (88–95 Nm) torque.

10. Tighten the four bolts (Fig. 7B–1, Item 4) to 90–100 ft.–lbs. (125–135 Nm) torque.

B–03521

Fig. 7B–2 Checking Alignment (Deutz F2L411D) –7B–2–

630, 631, 632 Loader Service Manual

7B–2 FUEL SYSTEM

1 7B–2.1 Fuel and Control Linkage Adjustment 1. Disconnect clevis from throttle lever at engine (Fig. 7B–3, Item 1).

2. Engage brake and start engine. Push throttle lever on engine forward until it is against the top. Check high idle. If not correct, turn the adjustment screw (Item 2) in or out as needed.

3. Pull the lever back so the leaf spring is in contact with the stop. Check low idle and make adjustment as needed.

2 B–03443

4. With the throttle lever pulled completely back (in the off position) turn the screw on the excess fuel lever so the fuel button is fully down (Fig. 7B–4).

Fig. 7B–3 Disconnecting Throttle Lever

5. Move the throttle control lever in the cab 1/8” (3,0 mm) from off position. Turn the clevis on the linkage rod in or out until it fits correctly.

6. Start the engine and run at full throttle. Drive the Bobcat against a stationary object to make the wheels turn, or engage parking brake.

7. Remove the cap and copper washer from the fuel adjustment screw (Fig. 7B–5). Turn the screw in or out until there is a small amount of smoke coming from the muffler. Tighten the lock nut on the screw.

8. Install the cap and washer.

C–02047

7B–2.2 Venting Air From Fuel System

Fig. 7B–4

Excess Fuel Lever

Air must be vented from the fuel system after the following conditions:

a.

Replacement of filters.

b.

Fuel system part replacement.

c.

Fuel tank is empty.

d.

Repair of leak in fuel line.

C–02048

Fig. 7B–5 Fuel Adjustment Screw (Deutz F2L411D) –7B–3–

630, 631, 632 Loader Service Manual

To vent air from fuel system: (Fig. 7B–6).

Slotted Plug

1

1. Fill tank with clean fuel.

2. Check in–line filter to be sure it is not dirty.

Priming Lever

3. Loosen fitting (1).

4. Move priming lever (2) until fuel comes from (1) free of bubbles.

Tighten fitting (1).

2 C–01895

Fig. 7B–6 Venting Fuel System

A–01593

Fig. 7B–7 Loosening Injector Fitting

5. Loosen injector fittings (Fig. 7B–7).

6. Turn the engine with starter until fuel comes from loose fittings.

7. Tighten the fittings again.

NOTE: Do not overtighten fittings.

7B–2.3 Fuel Filter (Fig. 7B–8) There are two fuel filters used in the fuel system (Fig. 7B–8).

IMPORTANT

KEEP The Fuel System CLEAN!

Fuel Filter

B–03219

Fig. 7B–8 Fuel Filters 1. Fuel Pump Strainer (Fig. 7B–9).

To clean the fuel pump strainer, remove the cover on the top of the pump.

The strainer and gasket can be lifted out and cleaned with compressed air.

2. Filter Cartridge (Fig. 7B–8).

To install new cartridge, put oil on the gasket. Tighten the filter by hand only.

Strainer

NOTE: When the filters are removed or if the Bobcat runs out of fuel, air will enter the fuel system.

7B–2.4 Fuel Lift Pump A repair kit is available for repair of the lift pump. If the pump does not give enough pressure, or if it leaks, install repair kit or have replacement made. (See Section 8 for correct pressure.) Check pressure by turning engine with starter.

(Deutz F2L411D) –7B–4–

PI–01758

Fig. 7B–9

Fuel Pump Strainer

630, 631, 632 Loader Service Manual

7B–2.5 Fuel Injection Pump Checking 1. Remove the tubelines to the injection pump.

2. Install a gauge loosely to one of the open connections. Turn the engine several revolutions to remove air from the gauge, then tighten the gauge. (Pressure indicator tool No. 3202 can be used [Fig. 7B–10]).

3. Close the throttle. Be sure the excess fuel button is released.

PI–02060

Fig. 7B–10 Pressure Indicator Tool

PI–01998

Fig. 7B–11 Removing Injector Pump

4. Turn the engine with the starter until the pressure on the gauge is 2130 PSI (14,700 kPa). Stop turning the engine. After one minute the pressure must be at least 1990 PSI (13,725 kPa).

5. Turn the engine about 5 more revolutions. The pressure on the gauge must be at least 4260 PSI (29,400 kPa).

If either pressure is low, the pump has defect.

7B–2.6 Removal of Fuel Injection Pump NOTE: The excess fuel button must be pressed before the pump is lifted out.

PI–02043

Fig. 7B–12 Adding or Removing Shims 1. Disconnect the fuel injection lines and the line from the fuel lift pump.

Remove the four nuts and remove the pump (Fig. 7B–11).

7B–2.7 Fuel Injection Pump Service The injection pump must be replaced as a unit if it has a defect.

7B–2.8 To Install Fuel Injection Pump 1. Put a gasket on the pump fastening surface.

2. Turn the camshaft so the cam lobes cannot be seen.

3. Measure the distance from the top of the gasket to the camshaft. Add shims on top of gasket until the distance is 3.248–3.256 inches (82,5–82,7 mm) (Fig. 7B–12 & Fig. 7B–13).

PI–02068

Fig. 7B–13 Adding or Removing Shims

4. Slide the fork so it is in alignment with the groove in the housing (Fig. 7B–14).

5. Install the fuel injection pump, and tighten the nuts. Connect the tubeline to the fuel lift pump.

6. Find top dead center this way: a. Put a piece of steel about 1/4” (6,0 mm) thick between a rocker arm and valve for No. 2 cylinder (farthest from the flywheel [Fig. 7B–15]).

PI–02044

Fig. 7B–14

Aligning Form With Groove

(Deutz F2L411D) –7B–5–

B–02201

Fig. 7B–15 Finding Top Dead Center (TDC) 630, 631, 632 Loader Service Manual

b. Turn the engine counterclockwise until the piston hits the valve. Put a mark on the pulley in line with the mark on the engine cover (Fig. 7B–16). Turn slowly to prevent damage to the valve. c. Turn the engine clockwise until the piston hits the valve again. Put another mark on the pulley in line with the mark on the engine cover.

PI–02052 d. Use a flexible measure (tape measure) to find the distance Fig. 7B–16 Marking Sheave W/Engine Cover between the marks on the pulley.

Put another mark exactly between the other two marks on the pulley (Fig. 7B–17).

B–02205

Fig. 7B–17 Marking Halfway Position

7. Put a mark 25° B.T.D.C. (This is 1.4 inches (35,6 mm) counterclockwise of the T.D.C. mark.) (Fig. 7B–18 & 7B–19).

8. Install the capillary tube (Deutz special tool No. 3209) in the injection pump fitting for No. 2 cylinder (farthest from the flywheel) (Fig. 7B–20).

NOTE: If the capillary tube is not available, the clear plastic cartridge for a ball point pen can be installed in the hole in the pump connection.

9. Vent the air from the system by turning the engine several revolutions with the starter, until fuel is coming up the clear tube.

10. Turn the engine in the direction of normal rotation slowly until fuel begins to show in the clear tube. When this happens, the 25° mark on the pulley will be in alignment with the mark on the front cover. If not, loosen the injection pump and slide it in or out for adjustment of injection timing (Fig. 7B–21).

N–01983

Fig. 7B–18 Marking Start Of Injection

Direction “A” = Later timing Direction “B” = Earlier timing 7B–2.9 Adjustment of Fuel Delivery 1. Engage the parking brake.

2. Start the engine and run at full throttle.

3. Actuate steering levers, until the engine begins to stall. There must be very little smoke coming from the muffler.

PI–02069

Fig. 7B–19 Aligned W/Dead Center Mark

Wrong adjustment of the fuel delivery will shorten the life of the engine. At high altitudes, the engine will have a rich mixture if the fuel delivery adjustment is not correct. This will damage the engine.

PI–02070

Fig. 7B–20

Removing Air From System

(Deutz F2L411D) –7B–6–

PI–02065

Fig. 7B–21 Adjusting Injection Timing 630, 631, 632 Loader Service Manual

7B–3 FUEL INJECTION NOZZLES 7B–3.1 Removal of Fuel Injection Nozzles 1. Remove the housing from around blower.

2. Disconnect the fuel lines.

3. Remove the bolt which holds the yoke down and lift out the yoke and washer (Fig. 7B–22 & 7B–23).

4. Pull the nozzle out. A nozzle puller can be used if necessary – Deutz P/N 110030 and 150800 (Fig. 7B–24).

PI–02021

7B–3.2 Disassembly & Repair of Fuel Injection Nozzles

Fig. 7B–22 Removing Set Screw

Special equipment is necessary for service of injection nozzles. Disassembly instructions are given only for cleaning and inspection.

1. Hold the body of the nozzle in a vise and turn off the bottom half. Slide the internal parts out and wash them in clean diesel fuel.

2. Use a soft brush to clean the tip.

3. Inspect the needle valve and its seat for wear or dirt.

4. Assemble the injector and check the release pressure and spray pattern with an injector tester. See Section 8 for specifications.

7B–3.3 Installation of Fuel Injection Nozzles Installation is the reverse of removal. Be sure to install a new sealing washer.

PI–02022

Fig. 7B–23 Removing Yoke and Washer 7B–4 ENGINE INFORMATION 1. All specifications are given in Section 8.

2. To check compression, install Deutz special tool No. 100020 in the injector opening (Fig. 7B–25).

3. During every overhaul, install new bearings in air blower.

4. Special bolts are used in several locations on the engine. These bolts are first tightened to 22 ft.–lbs. (30 Nm). Then tighten them in steps to the torque given.

5. Install new gaskets, o–rings and seals to prevent leaks.

PI–02023

Fig. 7B–24 Removing Injection Nozzle 6. Always install correct number of shims on each cylinder during assembly (Fig. 7B–26).

7B–5 ENGINE REMOVAL 1. Disconnect the fuel line, control linkage, negative and positive battery cables, air filter hose, throttle and wiring harness plug.

2. Remove the four bolts which hold the oil cooler to the engine. It is not necessary to disconnect the hoses.

PI–02024

Fig. 7B–25 Tool Fan checking Compression (Deutz F2L411D) –7B–7–

PI–02062

Fig. 7B–26 Cylinder Shims 630, 631, 632 Loader Service Manual

3. Remove the three bolts which hold the air housing to the crossmember. Connect a chain hoist to the engine. Remove the four bolts which hold the engine mounting plate to the frame.

Slide the engine back and out.

4. Installation is the reverse of removal.

7B–6 BLOWER FAN 7B–6.1 Removal (Fig. 7B–27)

PI–02051

Fig. 7B–27

IMPORTANT

Removing Blower

PI–02029

Fig. 7B–28 Loosening Bolt

Use care not to damage the fan blades. The fan is balanced.

1. Loosen the alternator to remove bolts.

2. Remove the idler bracket and three bolts which hold the blower in place. Lift the blower assembly off the engine.

7B–6.2 Installation PI–02061

Installation is the reverse of removal.

Fig. 7B–29 Removing Blower Fan

7B–6.3 Disassembly 1. Loosen the bolt (do not remove the bolt from the shaft) which holds the fan to the shaft (Fig. 7B–28). Using a soft hammer, hit the bolt (Fig. 7B–29) while holding the fan with the hand. Remove the bolt and lift out the fan out of the housing.

2. Using a soft hammer, hit the shaft until it comes out of the housing.

3. The bearing may come out with the shaft, if not use a puller to remove the bearing before you proceed to step 4.

4. Remove the snap ring from inside the housing and before you remove the bearing (a soft hammer and punch may have to be used) (Fig. 7B–30 & 7B–31)

PI–02036

5. If the bearing is still on the shaft use a puller to remove it.

Fig. 7B–30 Removing Snap Ring

7B–6.4 Assembly Assembly is the reverse of disassembly. Put high temperature grease in the bearings before assembly.

7B–7 CYLINDER HEAD AND VALVES 7B–7.1 Removal 1. Remove the blower and air housing.

2. Remove the manifolds and injection tubelines.

3. Remove the four bolts which hold the head in place with a socket (Loosen the bolts evenly.)

PI–02035

4. Lift the cylinder head off. The push rod tubes will come off with the head.

(Deutz F2L411D) –7B–8–

Fig. 7B–31 Removing Bearing 630, 631, 632 Loader Service Manual

7B–7.2 Disassembly 1. Remove the two bolts which hold the push rod tubes, and slide the tubes out.

2. Remove injectors. (See injector removal.)

3. Remove socket head screw which holds the rocker arms in place (Fig. 7B–32). Slide the bushings out and lift the rocker arms out (Fig. 7B–33).

PI–02011

Fig. 7B–32 RemovingRocker Arm Screen

PI–02012

Fig. 7B–33 Removing Bushing

4. Use a valve spring compressor to remove the valves and springs (Fig. 7B–34).

5. Remove the four socket head screws which hold the rocker arm to the head. (Loosen the screws evenly). Separate the two halves carefully.

PI–02013

Fig. 7B–34 Removing Valve Springs

PI–01982

Fig. 7B–35 Removing Damage

7B–7.3 Repair and Assembly 1. Inspect the head gasket surface for damage. Light scratches can be removed by grinding the head and he cylinder with fine grinding compound. Special tool No. 124410 is used when there is more damage (Fig. 7B–35).

2. If the old valves are not badly worn, they can be used again.

Check the clearance to the valve guides (Fig. 7B–36). If clearances are over maximum, heat the head to 250°C. and use tool No. 123310 to drive out guides (Fig. 7B–37).

Put the snap ring on the new guide and use drive tool to push it in place when the head is hot, until the snap ring hits the head (Fig. 7B–38). Use reamer No. 123510 to ream out new guide (Fig. 7B–39).

PI–02058

Fig. 7B–36 Checking Valve Guide Clearance

3. When guides are good, cut or grind the valve seats.

PI–02005

Fig. 7B–38

Installing Snap Ring

(Deutz F2L411D) –7B–9–

PI–02004

Fig. 7B–37 Removing Valve Guides

PI–02006

Fig. 7B–39 Using Reamer In Guide Bore 630, 631, 632 Loader Service Manual

4. Grind the old valves if you are going to use them again. Install the valve and measure the distance to the head. If the valve depth is over maximum, install a new valve. If new valve depth seat will need replacement (Fig. 7B–40). Tools No. 122900, 122970, 123820 (for inlet), 123830 (for exhaust) are needed to drill out old seat, and to install new seat. When the seat has been drilled, use a chisel as shown to remove it (Fig. 7B–41 & 7B–42).

Use the driver tool to push the new seat in place. First, heat the head to 250°C., then push cold seat in place. Grind or cut the new seat to be sure it is at a 90° angle to the guide.

PI–01984

Fig. 7B–40 Checking Valve Location

PI–02031

5. Put the four washers and gasket on the head and install the rocker chamber (Fig. 7B–43 & 7B–44).

Fig. 7B–42 Removing Valve Seat

PI–02017

6. Measure the valve springs for correct length (Fig. 7B–45).

7. Install new o–ring and washer as shown (Fig. 7B–46). Install valve, spring, cap and retainers with a valve spring compressor (Fig. 7B–47).

Fig. 7B–44 Installing Rocker Chamber

PI–02018

Fig. 7B–46 Installing Washer & O–Ring (Deutz F2L411D) –7B–10–

PI–02030

Fig. 7B–41 Drilling Valve Seat

PI–02007

Fig. 7B–43 Washers & Gasket

PI–02019

Fig. 7B–45 Checking Length of Valve Spring

PI–02020

Fig. 7B–47 Installing Valve Spring 630, 631, 632 Loader Service Manual

8. Check for wear in the rocker arms, if necessary, push out old bushings, and install new ones as shown (Fig. 7B–48).

NOTE: Be sure oil holes are in alignment.

PI–01997

7B–7.4 Installation of Cylinder Head

Fig. 7B–48 Installing Rocker

PI–02027

Fig. 7B–50 Checking Head Clearance

1. Put a piece of lead wire or solder across the piston as shown (Fig. 7B–49).

2. Install the head gasket and head.

Tighten the head bolts. Turn the engine one revolution. Remove the head and measure the thinner part of the wire, to find clearance between piston and head. If clearance is not correct, add or remove shims between cylinder and crankcase. (Be sure to have at least one shim on each side of spacer ring.) (See Fig. 7B–26).

PI–02064

Fig. 7B–51 Checking Head Bolt

PI–02047

Fig. 7B–51 Checking Alignment of Heads

3. Install the head again. Measure the bolts to see if any are beyond their limited length (Fig. 7B–50).

4. Hold a straight edge across the exhaust openings as shown (Fig. 7B–51). Move the cylinders until there is alignment.

PI–02063

5. Tighten the head bolts. Tool No. 4689 can be used to get correct angle for tightening (Fig. 7B–52).

Fig. 7B–52 Tightening Head Bolts

PI–02037

Fig. 7B–53 Seal Plate

6. Put new seals in the block and install the seal plate with the finished side down (Fig. 7B–53).

7. Put new seals on the pushrod tubes and slide the tubes in position (Fig. 7B–54). Install the set screws which hold the tubes down (Fig. 7B–55). Put the pushrods in the tubes.

PI–02038

Fig. 7B–54

Installing Tube For Pushrod

(Deutz F2L411D) –7B–11–

PI–02028

Fig. 7B–55 Set Screws For Tubes 630, 631, 632 Loader Service Manual

8. Hold the rocker arms in position.

Slide the rocker bushings in, and install the bolt. Make adjustment of the rocker arms (Fig. 7B–56).

9. Install all other parts removed during removal of head.

B–02197

7B–8 CYLINDERS, CONNECTING RODS

PISTONS,

Fig. 7B–56 Adjusting Rocker Arms

NOTE: Cylinders may be removed with or without the connecting rod and piston. It is best to remove and install piston, rod and cylinder together to prevent damage to parts.

1. Remove cylinder head.

2. Remove oil pan. Remove the bolts which hold the cap to the connecting rod. Mark the bearings to be used again (Fig. 7B–57).

PI–02025

Fig. 7B–57 Marking The Bearings

PI–02055

Fig. 7B–58 Removing Piston,Rod&Cylinder

3. Lift out the cylinder, piston and rod together (Fig. 7B–58). (Note the number of shims under the cylinder.)

4. Remove the piston from the cylinder and remove the snap rings from the piston. It may be necessary to heat the piston to push the piston pin out.

5. Remove the rings from the piston and clean the piston thoroughly.

Check the following for wear or damage:

N–02026

Fig. 7B–59 Checking Pin Bushing

PI–01991

Fig. 7B–60 Checking Rod Bearing

a. Piston and ring grooves b. Piston pin. c. Connecting rod bores and alignment (Fig. 7B–59, 7B–69 & 7B–61). d. Cylinder bore (check several places) (Fig. 7B–62).

Use a press to remove the bushing in the rod if it needs replacement (Fig. 7B–63).

PI–02015

Fig. 7B–61 Checking Rod (Deutz F2L411D) –7B–12–

PI–02016

Fig. 7B–62 Checking Cylinder Wall 630, 631, 632 Loader Service Manual

7B–8.1 Assembly 1. Refinish the cylinder and check it for size. Use a piston to push new rings into the bore, and check end gap of the rings (Fig. 7B–64).

2. Heat the piston to about 80°C. and install the piston pin through the rod and piston. Install the snap rings (Fig. 7B–65).

3. Put the rings on the piston with the mark on the rings upward. The chrome ring goes in the top groove. Turn the rings so the gaps are 120° apart.

N–02014

Fig. 7B–63 Removing Pin Bushing

4. Install the piston in the cylinder, with the open side of the rod on the pushrod side of cylinder (Fig. 7B–66).

5. If the old bearings will be used again, install them as marked during disassembly. If new bearings will be installed, use plastigage to check clearance of bearing to crankshaft.

PI–02048

Fig. 7B–64 Checking Ring Gap

Pushrod Side Of Cylinder

PI–02053

Fig. 7B–65 Installing Snap Ring

PI–02056

Fig. 7B–66 Rod in Cylinder

6. Install the shims and spacer on the cylinder as noted during disassembly. Put shims on both sides of the spacer where they will serve as gaskets (See Fig. 7B–26).

7. Slide the cylinder and piston assembly into the crankcase, using care not to damage the crankshaft surface. Install and tighten the rod cap.

8. Install the oil pan and gasket. Turn the engine top side up.

9. Install the head and remainder of parts. Be certain to check the clearance from the piston to the head. (See 7B–7.4 “Installation of Cylinder Head”.)

B–02203

Fig. 7B–67 Removing Bolt

7B–9 OIL PUMP, FILTER HOUSING AND RELIEF VALVE 7B–9.1 Oil Pump Removal 1. Remove the oil pan.

2. Remove the bolt that holds the pump (Fig. 7B–67).

3. Turn the pump as shown (Fig. 7B–68). Slide the pump out of the crankcase.

B–02204

Fig. 7B–68 Removing Oil Pump (Deutz F2L411D) –7B–13–

630, 631, 632 Loader Service Manual

7B–9.2 Installation Installation is the reverse of removal.

NOTE: The pump cannot be serviced. A new pump, with gear, must be installed if any part has a defect. Check end play to find the condition of the pump (Fig. 7B–69).

7B–9.3 Oil Pressure Relief Valve The oil pressure relief valve location is in the engine block (Fig. 7B–70). Do not change the length of the spring and do not add shims to the valve.

PI–02041

PI–02067

Fig. 7B–69 Checking End Play Of Oil Pump

Fig. 7B–70 Relief Valve For Oil Pressure

7B–9.4 Filter Housing To remove the filter housing, turn it out of the front cover. Be sure to install both o–rings new when the housing or front cover is removed (Fig. 7B–71).

7B–10 ENGINE FRONT COVER 7B–10.1 Removal

C–02038

Fig. 7B–71 Removing Filter Housing

PI–02039

Fig. 7B–72 End Plate & O–Ring Location

1. Remove the injection pump (See 7B–2.6 “Removal of Injection Pump”) 2. Remove the cooling blower, generator and pulley from governor shaft. Turn off the housing for the oil filter.

3. Remove the bolts (15 total) around the outside of the cover.

4. Lift off the front cover. Use care not to lose the dowel pins.

7B–10.2 Disassembly & Inspection

PI–02040

Fig. 7B–73 O–Rings On Plugs

PI–02045

Fig. 7B–74 Removing Cover Seal

1. Remove the hydraulic pump cover and install a new o–ring (Fig. 7B–72). Put new sealing washers under the two plugs (Fig. 7B–73).

”O” Ring

2. Remove the seal for the governor shaft and install a new one as shown (Fig. 7B–74 & 7B–75).

3. Check the excess fuel button and rubber cap for damage or wear.

Make replacement of the o–ring which holds the button in position.

Put grease in the groove for the o–ring (Fig. 7B–76).

PI–02046

Fig. 7B–75

Installing Cover Seal

(Deutz F2L411D) –7B–14–

PI–02071

Fig. 7B–76 Lubrication Of O–Ring 630, 631, 632 Loader Service Manual

4. If you replace the spring stop or spring for the excess fuel control, the spring must be turned 3/4 turn to give tension to the lever (Fig. 7B–77).

5. Drive the pin out of the throttle control lever, which holds it to the shaft (Fig. 7B–78).

PI–02072

Fig. 7B–77 Setting Spring Tension

PI–02034

Fig. 7B–78 Installing Pin

6. Remove the two bolts (new springs have four bolts) which hold the governor spring in position and the two snap rings which hold the arm in position. Slide the shaft out.

7B–10.3 Assembly 1. Slide the shaft into the cover and install the washer (Fig. 7B–79).

PI–02003

Fig. 7B–79 Installing Shaft For Throttle

PI–01999

Fig. 7B–80 Control Arm Linkage

2. Slide the shaft in more and install the control arm (Fig. 7B–80).

3. Slide the spring in and connect it as shown (Fig. 7B–81).

4. Slide the shaft in more and install the governor spring. Tighten the bolts which hold the spring in position (Fig. 7B–82).

PI–02000

Fig. 7B–81 Lever Spring

PI–02001

Fig. 7B–82 Installation Of Governor Spring

5. Install the snap rings on both sides of the control arm (Fig. 7B–83).

6. Install the O–ring on the shaft (Fig. 7B–84). Install the throttle lever and leaf spring on the shaft and use hammer to push the roll pin in position (Fig. 7B–85).

Revised Mar. 85

PI–02002

Fig. 7B–83

Installing Snap Rings

(Deutz F2L411D) –7B–15–

PI–02032

Fig. 7B–84 Installing O–Rings on Shaft 630, 631, 632 Loader Service Manual

7B–10.4 Installation 1. Put dowel pins and a new gasket on the front cover (Fig. 7B–86).

2. Put the distributor housing for the oil filter in the block. Turn it until it fits in place (Fig. 7B–87).

3. Put the spring in the front cover (Fig. 7B–88).

PI–02033

4. Measure the distance from the camshaft cam to the crankcase (Fig. 7B–89). Measure the distance from camshaft bearing in the cover to the gasket surface.

Include the thickness of the gasket in the measurement (Fig. 7B–90).

If the difference is more than .023” (0,584 mm), the front cover needs replacement.

Fig. 7B–85 Installing Roll Pin

PI–01990

Fig. 7B–86 Locating Dowel Pins

5. Put the cover into place and tighten the bolts evenly.

NOTE: The copper washer goes under the bolt shown in figure 7B–91.

PI–01986

PI–01985

Fig. 7B–87 Installing Distributor Housing

Fig. 7B–88 Installing Spring In Front Cover

6. Adjust the full and idle speeds (See Section 8).

7B–11 GOVERNOR

PI–01987

7B–11.1 Removal and Disassembly

Fig. 7B–89 Camshaft End Clearance

PI–02057

Fig. 7B–90 Clearance Of Cover & Camshaft

1. Remove the injection pump, blower and front cover. Slide the governor off the shaft.

2. Use two screwdrivers to push the gear and shaft out of the engine block (Fig. 7B–92).

3. Remove the wire clip disassemble the governor.

and

4. Inspect all parts for wear or damage.

PI–02054

Fig. 7B–91 Installing Front Cover (Deutz F2L411D) –7B–16–

B–02200

Fig. 7B–92 Removing Gear & Shaft 630, 631, 632 Loader Service Manual

7B–11.2 Assembly and Installation 1. Put grease on the inside ring to hold the balls in position. Install the balls. Slide the outer race over the balls (Fig. 7B–93).

2. Turn the bearing cup face down and install the shims with the tabs up (Fig. 7B–94). Slide the bearing assembly over the cup and shims, and install the snap ring (Fig. 7B–95).

3. Use a soft hammer to install the shaft and gear into the engine block. Be sure the timing marks are in alignment (Fig. 7B–96).

PI–02008

Fig. 7B–93 Governor Bearing Assembly

PI–02009

Fig. 7B–94 Installing Shims

4. Install the governor weights and the governor (Fig. 7B–97).

5. Install the remainder of parts removed.

7B–12 CAMSHAFT (Engine Must Be Removed) 7B–12.1 Removal 1. Remove the blower and air housing, the front cover and the rocker arm covers.

PI–02010

Fig. 7B–95 Retainer Ring

PI–01994

Fig. 7B–96 Alignment of Gears

2. Remove the rocker arms, pushrods and pushrod tubes.

3. Put the engine on its side so the exhaust manifold is up.

4. Remove the fuel lift pump.

5. Turn the engine crankshaft one revolution. Slide the camshaft out.

Use care not to damage the camshaft bearings.

6. Remove the oil pan. Slide the tappets out, and inspect all parts for wear or damage.

PI–01995

Fig. 7B–97 Installing Flyweights

PI–02049

Fig. 7B–98 Installing Camshaft Bearings

7. If bearings are good they can be used again. If not, use driver to push out the old ones, and install new. Use care to make alignment of the oil holes in the bushing with those in the block (Fig. 7B–98).

7B–12.2 Installation 1. Slide the tappets into their bores from inside the crankcase.

2. Put oil on the thrustwasher and slide it on the camshaft (Fig. 7B–99). Slide the camshaft into the engine, using care not to damage the bearings.

3. Install the fuel pump, pushrod tubes and pushrods. Install new rubber seals on both ends of the tubes.

4. Install the fuel pump, oil pan and other parts removed.

(Deutz F2L411D) –7B–17–

B–02198

Fig. 7B–99 Installing Thrust Washer 630, 631, 632 Loader Service Manual

7B–12.3 Crankshaft Removal 1. Remove the cylinders and pistons.

2. Remove the front cover and crankshaft gear (Fig. 7B–100).

3. Remove the flywheel and end cover (Fig. 7B–101).

4. Remove the bolt from the center main bearing. Slide the crankshaft out of the block.

5. Remove the center main bearing from the crankshaft (Fig. 7B–102).

B–02199

Fig. 7B–100 Removing Crankshaft Gear 7B–12.4 Crankshaft Inspection Clean all parts thoroughly and inspect for wear or damage.

1. Measure the crankshaft, and have it ground if necessary (See Section 8 “Technical Data” for specifications).

2. Install the correct bearing in the crankcase, center bearing, end plate and connecting rods.

3. Inspect the thrustwashers for wear or damage. Install new thrustwashers of the same thickness as those removed.

B–02202

Fig. 7B–101 Removing Flywheel & End Cover

PI–01988

Fig. 7B–102 InstallingCounterweights

7B–12.5 Crankshaft Assembly 1. Install the correct bearing into the block. Be sure the oil hole in the bearings is in alignment with the hole in the block (Fig. 7B–103).

NOTE: The bearing will be extended .055”–.065” (1,4–1,7 mm) outside the front of the block.

PI–02066

2. Put grease on the thrustwasher to hold it in position. Be sure the tang on the washer is in the slot in the block (Fig. 7B–104).

Fig. 7B–103 Installing Bearing

Tang

PI–01989

Fig. 7B–104 Installing Thrust Washer

3. Install bearings of the correct size in the center bearing support, and install the support on the crankshaft. Be sure the numbers on the support are together (Fig. 7B–105). Align the oil holes.

4. Slide the crankshaft into the block.

Use care not to damage the bearing in the block during installation. Be sure the hole in the bearing support is in alignment with the hole in block (Fig. 7B–106).

Revised Mar. 85

PI–02059

Fig. 7B–105 Bearing Support Check Marks (Deutz F2L411D) –7B–18–

PI–01993

Fig. 7B–106 Installing Crankshaft 630, 631, 632 Loader Service Manual

5. Install the bearing of the correct size in the end plate. Install the thrustwasher, seal and gasket. Be sure the hole in the bearing is in alignment with the hole in the plate. Slide the plate into place and install 2 or 3 bolts (Fig. 7B–107).

6. Measure the end movement of the crankshaft (Fig. 7B–108). If it is not within the specification, install shim gaskets or thrustwashers as needed, to get correct clearance. Use the same thrustwashers on both sides of crankshaft, or use one size thicker on the blower side.

7. Tighten all bolts in the end plate and the bolt in the bearing support. Turn the crankshaft to be sure it is free.

PI–01996

Fig. 7B–107 Installing End Plate

8. Install the cylinder and rod assemblies, the oil pan, the crankshaft gear and all other parts removed. Be sure the crankshaft gear fits on the pin in the crankshaft, and the timing marks are in alignment (Fig. 7B–109 & 7B–110).

7B–13 FLYWHEEL The ring gear for the starter is removed by cutting it with a chisel (Fig. 7B–111).

To install the new gear, heat it to about 200°C., and it will slide onto the cool flywheel.

PI–01992

Fig. 7B–108 Check End Play Of Crankshaft

B–02199

Fig. 7B–109 Installing Crankshaft Gear

PI–01994

Fig. 7B–110 Aligning Timing Marks (Deutz F2L411D) –7B–19–

630, 631, 632 Loader Service Manual

7B–14 ENGINE SERVICE (DEUTZ F2L511) 631 7B–14.1 TROUBLESHOOTING

TROUBLESHOOTING THE ENGINE PROBLEM Engine will not turn over with the starter.

Engine fails to start or is difficult to start.

CAUSE Battery has lost charge.

Charge battery.

Check the functions of charging system.

Loose battery connection.

Clean battery connections and cables. Tighten the clamps.

Loose starter connections.

Tighten the connections.

Defect in starter switch.

Make replacement of switch.

Broken or disconnected wiring harness.

Connect or make replacement of wiring.

Defective starter or solenoid.

Repair as needed.

Wrong starting procedure.

Refer to “Starting Procedure” in the Bobcat Operator’s Manual

No fuel in the tank.

Add fuel. Remove air from fuel system.

Air cleaner is dirty.

Service the air cleaner.

Fuel tank vent in cap has restriction.

Remove the cap and clean vent.

Fuel line has air leak or dirt, or water.

Correct as necessary.

Damaged fuel lift pump.

Make replacement of pump if needed.

Hydraulic–hydrostatic engine.

Engine misses, runs irregularly or stops.

CORRECTION

load

on

Put all controls in neutral and warm oil reservoir during very low temperatures.

Lever auxiliary pedal engaged.

Put auxiliary lever in neutral.

Defect in fuel injection system.

Check and needed.

Excess fuel function not working.

Check solenoid and adjust.

Crankcase oil is thick.

Use engine oil of correct viscosity (See Oil Specification Chart).

Fuel injection set wrong.

Check timing.

Dirty fuel mixture, or restriction in fuel filter or vent.

Clean as necessary.

Poor compression.

Check for loose cylinder head bolts.

Water in the fuel.

Drain and replace fuel. Replace fuel filters.

(Deutz F2L511) –7B–20–

make

repairs

as

630, 631, 632 Loader Service Manual

PROBLEM Engine overheats.

CAUSE Engine is overloaded.

CORRECTION Operate in low range. Operate at rated RPM. Remove covers and clean cooling fans.

Clean cooling fins and install the covers.

Make replacement of engine oil.

Correct as necessary.

Check fuel injection.

Tighten mount bolts to correct torque.

Replace rubber mounts.

Engine cooling fins are dirty.

Too much engine vibration.

Engine has been operated with part of covers removed.

Dirty engine oil.

Exhaust system has restriction.

Injection timing is wrong.

Loose engine mounts.

Worn rubber mounts.

7B–15 ENGINE MOUNTS 1. Lubricate (with soap and water) the outside of the rubber mounts (Fig. 7B–112, Item 1) and install them into the engine mounts.

2. Install the front mount on the engine. Use a liquid adhesive (”Loctite”) on the bolts. Tighten the three bolts (Fig. 7B–112, Item 2) to 90–100 ft.–lbs.

(125–135 Nm) torque.

3. Install the rear mount on the engine. Use a liquid adhesive (”Loctite”) on the bolts. Tighten the four bolts (Fig. 7B–112, Item 3) with your hand only.

4. Install the engine into the loader.

6 Rear Mount

Front Mount

5. Move the engine to align the universal joint between the engine and the hydrostatic pump.

6. Put washers on the two bolts that go into the rear mount of the engine.

7. Install all four bolts (Fig. 7B–112, Item 4) through the bottom of the engine compartment and into the engine mounts. Put the washers (Fig. 7B–112, Item 6) and the nuts on the bolts, but do not tighten them yet.

5 3

2 4

1 E–1186R

Fig. 7B–1

Rubber Mounts

8. Check the alignment of the U–joint.

To check the alignment of U–joint: (a) Remove the seat. (b) Remove the pan (shield) the seat was fastened to. (c) Put a short piece of straight flat material (key stock) against the flat surfaces (side and top) of the U–joint (Fig. 7B–113). (d) Move the engine so it will be in parallel alignment with the pump. It must not be more than .25 in. (6,35 mm) out of parallel alignment.

Key Stock

9. Tighten the four bolts (Fig. 7B–112, Item 3) on the rear mount of the engine to 65–70 ft.–lbs. (88–95 Nm) torque.

10. Tighten the four bolts (Fig. 7B–112, Item 4) to 90–100 ft.–lbs. (125–135 Nm) torque.

Key Stock

7B–16 FUEL SYSTEM 7B–16.1 Fuel System 1. Engage parking brake and start engine. Push throttle forward until it is against the stop. If it is not against the stop remove and adjust clevis (Fig. 7B–114, Item 1). High idle must be 2625–2675 RPM. If not correct turn adjustment screw.

(Deutz F2L511) –7B–21–

B–03531

Fig. 7B–113

Disconnecting Throttle

630, 631, 632 Loader Service Manual

2. Adjust clevis (Fig. 7B–114, Item 1) so when the solenoid is in full down position the fuel button is fully engaged. The clearance between the top of the button and button guide collar must be .0312 (.79 mm).

1

3. Check adjustment by pushing down on the solenoid rod. The lever must not bottom out on the collar around the fuel excess button.

1

4. If the lever bottoms out, the rod must be adjusted until there is a small gap of .0312 (.79 mm).

NOTE: It is important the linkage is adjusted so the plunger in the solenoid is in a full down position when engaged. If not there will be damage to the solenoid.

7B–16.2 System

Venting

Air

from

B–03175R

Fig. 7B–114 Fuel Solenoid Installed

B–03218

Fig. 7B–115 Venting Fuel System

Fuel

Air must be vented from the fuel system after the following condition.

Replacement of Filters 1. Fuel system parts replacement.

2. Fuel tank is empty.

3. Repair of fuel line.

To Vent Air from Fuel System (See Fig. 7B–115) 1. Fill tank with clean fuel.

2. Check in–line filter and fuel line for dirt. Both must be clean and free of any foreign material.

3. Loosen slotted plug (Fig. 7B–115, Item 1).

4. Move priming lever (Fig. 7B–117, Item 1) until fuel flows constant and free of air from slotted plug (Fig. 7B–115, Item 1). Tighten fitting (Item 1).

A–01593

5. Loosen injector fittings (Fig. 7B–116).

Fig. 7B–116 Loosening Injector Fitting

6. Turn the engine with starter until fuel comes from loose fittings.

7. Tighten the fittings again.

NOTE: Do not overtighten fittings.

Strainer

7B–16.3 Fuel Filters (Fig. 7B–118)

IMPORTANT

KEEP The Fuel System CLEAN!

1 PI–01752

Fig. 7B–117 Fuel Lift Pump Strainer (Deutz F2L511) –7B–22–

630, 631, 632 Loader Service Manual

There are two fuel filters used in the fuel system.

1. Fuel pump strainer (Fig. 7B–117).

To clean the fuel pump strainer remove the cover on the top of the pump. The strainer and gasket can be lifted out and cleaned with compressed air.

2. Filter Cartridge (Fig. 7B–118).

To install a new cartridge, remove the housing. Remove the old cartridge and install the new filter cartridge.

NOTE: When the filters are removed or if the engine runs out of fuel, air will enter the fuel system and venting is necessary. Check for leaks.

7B–16.4 Fuel Lift Pump

Filter

A repair kit is available for repair of the lift pump. If the pump does not give enough pressure or it leaks, install repair kit or make a replacement (See Section 8 for correct pressure by turning the engine with the starter).

7B–16.6 Removal of Fuel Injection Pump

B–03219

Fig. 7B–118 Fuel Filter

Checking Delivery Valves and Pump Elements 1. Remove the fuel injection lines from the injection pump.

2. Install pressure indicator tool loosely to one of the open connections. Turn the engine several revolutions to remove air and tighten.

3. Open the throttle.

4. Turn the engine with the starter until the pressure on the gauge is as least 1073.5 PSI (150 bar). Wait for one minute. The pressure drop must not be more than 145 PSI (10 bar) on the delivery valve.

5. Turn the engine 5 revolutions. The pressure shown on the gauge must be at least 4347 PSI (300 bar) on the pump elements.

If either pressure is low, the pump has a defect.

7B–16.6 Removal of Injection Pump NOTE: The excess fuel button must not be engaged.

1. Disconnect the fuel injection lines and the fuel lift pump. Remove the four nuts and remove the pump (Fig. 7B–120).

7B–16.7 Fuel Injection Pump Service N–02411

The injection pump must be replaced as a unit if it has a defect.

Fig. 7B–119 Pressure Indicator Tool

7B–16.8 To Install Fuel Injection Pump

3.252–3.256 (82,6–82,7 mm)

1. Put a new gasket on the pump fastening surface.

2. Turn the camshaft so the cam lobes cannot be seen.

3. Measure the distance from the top of the gasket to the camshaft (Fig. 7B–121). Add shims on the top of the gasket until the distance is 3.252–3.256 (82,6–82,7 mm) (Fig. 7B–122).

N–02412

Fig. 7B–120 Removing Injector Pump (Deutz F2L511) –7B–23–

PI–02452

Fig. 7B–121 Distance Camshaft to Gasket 630, 631, 632 Loader Service Manual

4. Align the fork of the control lever with the recess in the engine housing (Fig. 7B–124).

5. Align the ball on the pump rack (Fig. 7B–123) with the recess in the engine casing.

6. Install the injection pump and connect the fuel line using new gaskets on both sides of the banjo fitting.

N–02413

Fig. 7B–122 Adding or Removing Shims

N–02414

Fig. 7B–123 Moving the Rack

Use this procedure to find top dead center (TDC). (a) Check the valve clearance and correct as needed. Clearance must be .006” (9.15 mm).

(b) Turn the pulley counterclockwise so that the piston of cylinder #2 (closest to the pulley) is at the point of maximum compression (TDC).

N–02412

Fig. 7B–124 Aligning the Fork

(c) Turn the pulley clockwise 45°. Press down one of the valves on cylinder #2 with a screwdriver. Put a piece of 1/4” (5,6 mm) steel between the valve stem and the rocker arm.

(d) Turn the pulley counterclockwise by hand until the piston hits the protruding valve.

B–02201

IMPORTANT

Turn the pulley at a slow rate. Be careful not to damage the valve or piston.

Fig. 7B–125 Finding Top Dead Center (TDC)

(e) Put a mark on the pulley in line with the engine cover (Fig. 7B–126).

Turn the pulley clockwise about 45° and remove the steel.

(f) Turn the front pulley through TDC (90°) counterclockwise. Put the 1/4” (5,6 mm) in between the same valve stem and rocker. Carefully rotate the pulley clockwise until the piston again hits the valve. Put a mark at this position (Fig. 7B–126). Turn the pulley counterclockwise 45° and remove the steel.

(Deutz F2L511) –7B–24–

PI–02052

Fig. 7B–126 Marking Sheave 630, 631, 632 Loader Service Manual

(g)

Assemble the cylinder head covers.

(h) Use a steel flexible rule to mark and measure the half–way position between the two marks (Fig. 7B–127). This is top dead center.

NOTE: When the center mark on the pulley is in line with the mark on the housing, #2 piston is TDC.

IMPORTANT

Turn the pulley at a slow rate. Be careful not to damage the valve or piston.

N–02415

Fig. 7B–127 Marking Halfway Position

7. Make a mark 22° B.T.D.C. (This is 1.126” (28,6 mm) counterclockwise of the TDC mark (Fig. 7B–128).

8. Install the capillary tube (Deutz special tool P/N 003–1085 in the injection pump fitting for #2 cylinder (closest to the pulley (Fig. 7B–129).

NOTE: If the capillary tube is not available the clear plastic cartridge for a ball point pen can be installed in the hole of the pump connection.

9. Vent the air from the fuel system by turning the engine several revolutions with the starter, until fuel is coming up the tube free of air.

10. Turn the engine in the direction of normal rotation at a slow rate until fuel begins to show in the clear tube. When this happens this 22° mark on the pulley must be in alignment with the mark on the housing (Fig. 7B–130). If it is not loosen the injection pump and slide it in or out for adjustment of injection timing (Fig. 7B–131).

N–01983

Fig. 7B–128 Marking Start of Injection

Direction “A” = Advanced Timing Direction “B” = Retard Timing

7B–16.9 Adjustment of Fuel Delivery 1. Engage the parking brake.

2. Start the engine and run at full throttle.

PI–02070

3. Push the levers forward at a slow rate until the engine begins to stall. There must be very little black smoke coming from the muffler.

Wrong adjustment of the fuel delivery will shorten the life of the engine. At high altitudes, the engine will have a rich mixture if the fuel delivery adjustment is not correct. This will damage the engine.

PI–02069

Fig. 7B–130 Aligned with Start of Injection (Deutz F2L511) –7B–25–

Fig. 7B–129 Removing Air From System

N–02436

Fig. 7B–131 Adjusting Injection Timing 630, 631, 632 Loader Service Manual

4. If fuel adjustment is not correct at high altitude (Too much black smoke) put the levers in neutral position. Remove the cap and copper washer from the fuel adjustment screw (Fig. 7B–123). Turn the screw in or out until there is a small amount of black smoke coming from the muffler. Tighten the locknut on the screw.

5. Install the cap and washer.

7B–17 FUEL INJECTION NOZZLES C–02048

7B–17.1 Removal

Fig. 7B–132 Fuel Adjustment Screw

1. Disconnect the fuel lines.

2. Remove the nut that holds the yoke in position and remove the yoke (Fig. 7B–133).

3. Pull out the nozzle. A nozzle puller can be used if necessary (P/N 003–0463 – Extractor and 003–0536 – Slide Hammer) (Fig. 7B–134).

7B–17.2 Disassembly and Repair of Injector (In Shop) Special equipment is needed for service of injection nozzles. Disassembly instructions are given only for cleaning and inspection.

N–02416

Fig. 7B–133 Removing the Yoke 1. Clamp body of the injector valve in a vise. Unscrew the lower parts (Fig. 7B–135) and remove the internal parts very carefully. Wash them in clean diesel fuel.

2. Use a stiff bristle brush to clean the tip.

IMPORTANT

Do not use steel brushes to clean the injector tips.

N–02417

Fig. 7B–134 Removing Injectors 3. Inspect the needle valve and needle valve seat for wear or dirt. Replace if either one is damaged.

4. Assemble the injector and check the release pressure and spray pattern with an injector tester (See section 8B–1.10 for specifications).

7B–17.3 Installation of Injector Installation is the reverse of removal.

NOTE: A new sealing gasket MUST be used each time an injector is replaced.

(Deutz F2L511) –7B–26–

PI–02464

Fig. 7B–135 Disassembly Of Injection Nozzle 630, 631, 632 Loader Service Manual

7B–18 ENGINE INFORMATION 1. All specifications are given in section 8 “511 Technical Data”.

2. To check compression install compression tester in the injector opening (Fig. 7B–136).

3. Install new bearings in the air blower every time the engine is overhauled.

4. Special bolts are used in many locations. These bolts are first tightened to 22 ft.–lbs. (30 Nm) torque. Then tighten them in steps to correct torque (See section 8 “511 Technical Data”.

5. When overhauling an engine always install new gaskets, o–rings and seals.

N–02418

Fig. 7B–136 Tool For Checking Condenser 6. Install the correct number of shims on each cylinder during assembly (Fig. 7B–137).

NOTE: Check piston clearance to determine number of shims.

7B–19 ENGINE REMOVAL To remove engine from Bobcat: 1. Disconnect battery cables (Negative must be disconnected first).

2. Disconnect the ground from the frame.

3. Disconnect wires from the solenoid.

PI–02062

Fig. 7B–137 Cylinder Shims 4. Disconnect air cleaner hose.

5. Disconnect exhaust pipe.

6. Disconnect the two fuel lines, the inlet and the return.

7. Disconnect throttle linkage.

8. Remove the four bolts holding the engine mounts on the plate.

9. Remove engine from machine by lifting up a small amount on the rear of the engine and pulling engine out carefully.

10. Installation is the reverse of removal.

7B–20 BLOWER FAN 7B–20.1 Removal of Blower Fan

IMPORTANT

Do not use steel brushes to clean the injector tips.

1. Loosen the alternator to remove belts.

2. Remove the alternator bracket and the three bolts that hold the blower in position (Fig. 7B–138). Lift the blower assembly off the engine.

(Deutz F2L511) –7B–27–

N–02419

Fig. 7B–138 Removing Bolts 630, 631, 632 Loader Service Manual

7B–20.2 Installation Installation is the reverse of removal.

7B–20.3 Disassembly 1. Clamp the pulley of the cooling fan in a vice with protective aluminum jaws and unscrew the center bolt (Fig. 7B–139).

2. Remove the blower fan (Fig. 7B–140).

N–02420

Fig. 7B–139 Removing Center Bolt

PI–02061

Fig. 7B–140 Removing Blower Fan

3. Remove the drive shaft from the fan housing with a soft metal drift punch.

4. Remove the ball bearing from the drive shaft using a bearing puller.

5. Remove the snap ring (Fig. 7B–141) from the ball bearing in the housing.

Remove the ball bearing using a soft metal drift punch (Fig. 7B–142).

7B–20.4 Assembly 1. Fill the new bearing with high temperature bearing grease.

N–02421

Fig. 7B–141 Removing Snap Ring

2. Press the small bearing into the fan housing with the closed side down.

3. Install the snap ring to hold the bearing in position.

4. Press the large ball bearing over the drive shaft with the closed side toward the V–belt pulley.

5. Press the fan shaft (with the bearing on) into the housing.

6. Clamp the cooling fan in a vice by the pulley.

N–02422

Fig. 7B–142 Removing Bearing 7. Position the rotor wheel and tighten the bolt to correct torque as specified in Technical Data.

7B–21 CYLINDER HEAD AND VALVES 7B–21.1 Removal and Disassembly 1. Remove the blower and air housing.

2. Remove the manifold and injector lines.

3. Remove the valve covers and the rocker arm brackets (Fig. 7B–143).

(Deutz F2L511) –7B–28–

N–02423

Fig. 7B–143 Removing Rocker Arm Bracket 630, 631, 632 Loader Service Manual

4. Remove the plugs and push rods (Fig. 7B–144).

5. Remove the four bolts that hold the head in position with a socket wrench (Loosen the bolts evenly).

6. Lift the cylinder head off and remove the push rod cover tubes.

N–02424

Fig. 7B–144 Removing the Plugs

N–02425

Fig. 7B–145 Removing Valve Springs

7. Use a valve spring compressor to remove the valves and springs (Fig. 7B–145).

7B–21.2 Repair and Assembly 1. Check the head seating surface for damage (Fig. 7B–146). Light scratches can be removed by grinding the head on the cylinder with fine grinding compound.

Special tool (P/N 003–0426) is used when there is more damage.

2. Grind the old valves, if you are going to use them again. Install the valve and measure the distance to the head. If the valve depth is over maximum the valve seat will need to be replaced (Fig. 7B–147). Use valve seat removal tool kit (P/N 003–3409).

(a)

N–02426

Fig. 7B–146 Checking Surface

N–02427

Fig. 7B–147 Checking Valve Depth

B–03488

Fig. 7B–148 Removing Valve Guides

Heat the cylinder head to 450°F. (250°C.) in an oven.

(b) Remove the head from the oven. Put it on its side and while holding with asbestos gloves tap out the valve guides from the bottom (piston side) with a punch (Fig. 7B–148).

(c)

Install valve seat removal tool into the valve seat (Fig. 7B–149).

B–03487

Fig. 7B–149 Tool For Removal Valve Seat (Deutz F2L511) –7B–29–

630, 631, 632 Loader Service Manual

(d) Put the punch through the bore of the valve and guide into the removal tool. Then remove the valve seat (Fig. 7B–150).

(e) Check the cylinder head temperature. It must be 450°F. (250°C). Using a punch install new guides (Fig. 7B–151).

B–03484

Fig. 7B–150 Removing Valve Seat NOTE: The snap ring on the guide must contact the head to be installed correctly.

B–03485

Fig. 7B–151

Installing New Guide

(f) Install a new valve seat (Fig. 7B–152) into the core and tap into position using the special tool from the Kit (P/N 003–3409).

NOTE: Never use too much force when installing valve guides and seats. The cylinder head must be heated to correct temperature and there must not be any debris (burrs).

3. Measure the valve springs for correct length (Fig. 7B–153).

B–03486

Fig. 7B–152 Installing New Seat

4. Apply lubricant (oil) to valve stems and install them. Install the spring caps (Fig. 7B–154), springs and retainer with a spring compressor.

N–02410

Fig. 7B–153 Valve Spring Length

5. Disassemble the rocker arms from the bracket to check for wear (Fig. 7B–155). Install new bushings if needed.

NOTE: The oil aligned.

holes

must

N–02428

be

Fig. 7B–154 Installing Spring Caps (Deutz F2L511) –7B–30–

N–02429

Fig. 7B–155 Checking Bushing 630, 631, 632 Loader Service Manual

7B–21.3 Checking Piston Crown Clearance and Installation of Cylinder Head Lead Wire 1. Position lead wire on solder (Approximate diameter .060” min.) across the piston as shown on Figure 7B–156.

IMPORTANT

Use grease to hold the solder in position. The piston must be below TDC. N–02430

Fig. 7B–156 Checking Clearance 2. Put the cylinder head on and install the head bolts with washers. (a) Preload bolts to 22 ft.–lbs. (30 Nm) torque (See tightening procedure) and tighten all head bolts through the first step with a degree scale tool (P/N 003–0500). Turn engine one complete revolution (360°). (b) Remove the head bolts and the head (Mark heads relative to cylinders). (c) Remove the lead wire and gauge the thinnest points. If clearance is not correct add or remove shims between cylinder and crankcase. (See Piston Crown Clearance, Page 8B–5).

N–02431

Fig. 7B–157 Checking Alignment of Heads

NOTE: When installing head use this method to get correct clearance.

If the clearance is not enough remove the cylinder and put the number of shims needed below the liner.

If the clearance is too large raise the cylinder and remove the correct amount of shims.

N–02432

Use one thick shim instead of several thin ones.

Fig. 7B–158 Tightening Head Bolts

3. Before installing the heads measure the bolts for proper length (See Engine Specifications).

4. Hold a straight edge across the top of the heads as shown in Figure 7B–157.

Move the cylinder heads until there is alignment.

5. Tighten the head bolts. Tool P/N 003–0500 must be used to get the correct angle for tightening (Fig. 7B–158) (See Torque Specifications, Section 8B–1.18).

6. Install the spring on the push rod tube by using tool P/N 003–0501 (Fig. 7B–159).

N–02435

Fig. 7B–159 Installing Spring (Deutz F2L511) –7B–31–

630, 631, 632 Loader Service Manual

7. Put the washer and seal on the bottom of the push rod tube and a seal at the top (Fig. 7B–160).

8. Install the push rod tubes as shown in Figure 7B–161.

9. Install the push rods and the rocker arm bracket. Make adjustment of the rocker arms (Fig. 7B–162).

N–02433

Fig. 7B–160 Installing Washer

10. The rocker arms have an oil metering screw (Fig. 163). One thread must be showing over the top of the nut. There must be a small amount of oil flow toward the thrust pad.

7B–22 CYLINDER, PISTONS AND CONNECTING RODS N–02434

Fig. 7B–161 Installing Push Rod Tubes NOTE: Cylinders may be removed with piston and connecting rod in position. It is best to remove and install the piston rod and cylinder together to prevent damage to parts.

N–02409

Fig. 7B–162 Adjusting Rocker Arms

Metering Screw

1. Remove the cylinder head.

2. Remove oil pan. Remove the bolts that hold the cap to the connecting rod. Mark the bearings if they are to be used again (Fig. 7B–164).

B–03537

Fig. 7B–163

Oil Metering Screw

PI–02025

Fig. 7B–164

Marking

3. Lift out the cylinder, piston and rod together (Fig. 7B–165) (Note the number of shims under the cylinder).

4. Remove the piston from the cylinder and remove the snap rings holding the piston pins. It may be necessary to head the piston and push the piston pin.

5. Remove the rings from the piston and clean the piston. Check the following for wear or damage: (a) Piston and ring grooves.

PI–02055

(b) Piston pin.

Fig. 7B–165 Remove Piston, Rod, Cylinder (Deutz F2L511) –7B–32–

630, 631, 632 Loader Service Manual

(c) Connecting rod bores and alignment (Fig. 7B–166, 7B–167, 7B–168).

(d) Cylinder bore (Check several locations) (Fig. 7B–169).

Use a press to remove the bushing from the rod if it needs replacement (Fig. 7B–170).

N–02026

Fig. 7B–166 Checking Pin Bushing

PI–01991

Fig. 7B–167 Checking Rod Bearing

7B–22.1 Assembly 1. Hone the cylinder and check it for size. Use a piston to push rings onto the bore to check end gap of the rings (Fig. 7B–171).

PI–02015

2. Assemble the piston as shown in (Fig. 7B–172). The arrow on the top of the piston must be pointed toward the long side of the piston rod (Fig. 7B–172). Install the piston pin through the rod and piston and install the snap rings.

Fig. 7B–168 Check Rod

PI–02016

Fig. 7B–169 Checking Cylinder Wall

3. Install snap rings on the piston with the mark on the ring toward the top. Turn the rings so the gaps are 120° apart.

N–02014

Fig. 7B–170 Removing Pin Bushing

PI–02048

Fig. 7B–171 Checking Ring Gap

4. Install the piston in the cylinder with the arrow on the top of the piston, pointing toward the exhaust side of the engine (Fig 7B–173). Use ring compressor tool (P/N 003–0430).

5. If the old bearings are to be used again, install them as marked. If new bearings are to be installed, use plastic gauge to check clearance of bearing to crankshaft.

N–02493

Fig. 7B–172 Piston Assembly (Deutz F2L511) –7B–33–

N–02437

Fig. 7B–173 Arrow on Piston 630, 631, 632 Loader Service Manual

6. Install the shims on the cylinder as noted during disassembly (Fig. 7B–174).

7. Position the cylinder and piston assembly into the crankcase, using care not to damage the crankshaft surface. Install and tighten the rod cap (See Torque Specifications, Page 7B–6).

8. Install the heads and the remainder of parts. Check piston crown clearance (See 7B–21.3, Cylinder Heads).

N–02439

7B–23 OIL PUMP, FILTER HOUSING AND RELIEF VALVE

Fig. 7B–174 Installing Shims

7B–23.1 Oil Pump Removal 1. Remove the oil pan and front cover.

2. Remove the bolt that holds the oil pump in location (Fig. 7B–175).

3. Remove crankshaft gear.

4. Remove breather pipe.

5. Turn the pump as shown in Figure 7B–176. Remove the pump from the crankcase.

N–02440

Fig. 7B–175 Removing Bolt

7B–23.2 Installation Installation is the reverse of removal.

NOTE: The pump cannot be serviced. A new pump (with gear) must be installed if any part has a defect. Check end play to find the condition of the pump (Fig. 7B–177) (See Engine Specifications, Section 8).

7B–23.3 Oil Pressure Relief Valve The oil pressure valve is located in the engine block. Do not charge the length of the spring and do not add shims to the valve.

N–02441

Fig. 7B–176 Removing Oil Pump

7B–24 ENGINE FRONT COVER 7B–24.1 Removal 1. Remove the injection pump (See Section 7B–16.3, Removal of the Injection Pump).

2. Remove the cooling blower, generator and pulley from governor shaft.

3. Remove the bolts around the outside of the cover.

4. Lift off the front cover. Be careful not to lose the dowel pins.

(Deutz F2L511) –7B–34–

PI–02041

Fig. 7B–177 Checking End Play Of Oil Pump 630, 631, 632 Loader Service Manual

7B–24.2 Inspection

Disassembly

and

1. Remove the end plate and install a new o–ring (Fig. 7B–178). Put new sealing washers under the two plugs (Fig. 7B–179).

2. Remove the old seal from the governor shaft and install a new one as shown in (Fig. 7B–180, 7B–181).

PI–02442

Fig. 7B–178 End Plate and O–ring Location

PI–02040

Fig. 7B–179 O–rings on Plugs

3. Check the excess fuel button for damage or wear. Replace o–ring and put grease on center groove for o–ring (Fig. 7B–182).

N–02463

4. If you replace the spring on the excess fuel control, the spring must be turned 3/4 of a turn to give tension to the lever (Fig. B–183).

Fig. 7B–180 Removing Cover Seal

N–02443

Fig. 7B–181 Installing Cover Seal

5. Remove the pin from the throttle control lever, and remove the lever from the shaft (Fig. 7B–184).

PI–02071

Fig. 7B–182 Lubrication of O–ring

PI–02072

Fig. 7B–183 Setting Spring Tension

6. Remove the two bolts which hold the governor spring in position and the two snap rings which hold the arm in position. Remove the shaft.

7B–24.3 Assembly 1. Slide the shaft into the cover and install the washer (Fig. 7B–185).

N–02444

Fig. 7B–184 Removing Pin (Deutz F2L511) –7B–35–

PI–02003

Fig. 7B–185 Installing Shaft Bolt 630, 631, 632 Loader Service Manual

2. Put the shaft in position to install the control arm (Fig. 7B–186).

3. Put the spring on and connect it as shown in Figure 7B–187.

PI–01999

Fig. 7B–186 Control Arm Linkage

PI–02000

Fig. 7B–187 Lever Spring

4. Move the shaft in more and install the governor spring. Tighten the bolts which hold the spring in position (Fig. 7B–188).

5. Install a snap ring on each side of the control arm (Fig. 7B–189).

N–02445

Fig. 7B–188 Installing Governor Spring

N–02446

Fig. 7B–189 Installing Snap Rings

6. Install the o–ring on the shaft (Fig. 7B–190). Install the throttle lever and leaf spring on the shaft and install locking pin (Fig. 7B–191).

PI–02032

Fig. 7B–190 Installing O–rings on Shaft

N–02447

Fig. 7B–191 Installing Roll Pin

7B–24.4 Installation 1. Put dowel pins in front cover and apply gasket sealant (Fig. 7B–192).

Casket Sealant

Dowel Pins A

2. With the camshaft pressed against its contact face measure the distance “a” from the front of the collar to the front of the engine housing (Fig. 7B–193).

B–03538

Fig. 7B–192 Location of Dowel Pins (Deutz F2L511) –7B–36–

PI–02449

Fig. 7B–193 Checking End Clearance 630, 631, 632 Loader Service Manual

3. Measure the distance “b” between the stop and the joint surface of the front cover (Fig. 7B–194).

4. Dimension “b” must be more than dimension “a”. The maximum must not be more than .024 inches (.6 mm). If it is a new front cover it must be fitted.

5. Install the cover bolts and tighten them evenly.

PI–02057

6. Adjust high and low idle speeds (See Page 8B–8).

Fig. 7B–194 Clearance Of Cover & Camshaft

7B–25 GOVERNOR 7B–25.1 Removal and Disassembly 1. Remove the injection pump, blower and front cover. Remove the governor shaft.

2. Use two screwdrivers to remove the gear and shaft from the engine block.

N–02450

Fig. 7B–195 Governor Bearing 3. Remove the wire retainer and disassemble the governor.

4. Check all parts for wear or damage.

7B–25.2 Assembly and Installation 1. Put grease on the inside ring to hold the balls in position. Install the balls. Put the outer race over the balls (Fig. 7B–195).

N–02451

2. Turn the bearing cup face down and install the shims with the tabs up (Fig. 7B–196). Position the bearing assembly over the cup and shims and install the snap ring (Fig. 7B–197).

Fig. 7B–196 Installing Shims

3. Use a soft hammer to install the shaft and gear into the engine block. The timing marks must be in alignment (Fig. 7B–198).

4. Install the governor weights and the governor (Fig. 7B–199).

5. Install the remainder of the parts removed.

N–02453

Fig. 7B–197 Retainer Ring (Deutz F2L511) –7B–37–

N–02454

Fig. 7B–198 Alignment of Gears 630, 631, 632 Loader Service Manual

7B–26 CAMSHAFT (Engine Must Be Out of Machine) 7B–26.1 Removal 1. Remove injection pump.

2. Remove the blower and air housing, the front cover and the rocker arm covers.

3. Remove the rocker arms and push rods.

N–02455

Fig. 7B–199 Installing Flyweights

N–02457

Fig. 7B–200 InstallingCamshaft Bearings

4. Put the engine on its side so the exhaust manifold is up.

5. Remove the fuel lift pump.

6. Remove the camshaft. Be careful not to damage the camshaft bushing (See Page 8B–4).

7. Remove the oil pan. Remove the tappets (Check all parts for wear or damage).

8. If the bushing is good, it can be used again. If not, use a driver to push out the old one and install a new one. Align the oil holes in the bushing with those in the block when you install a new bushing (Fig.7B–200).

B–02198

Fig. 7B–201 Installing Thrustwasher

7B–26.2 Installation 1. Position the tappets into their bores from inside the crankcase.

2. Put oil on the thrustwasher and put it on the camshaft (Fig. 7B–201).

3. Install oil pan. Turn engine upright.

4. Install the fuel lift pump, push rods and rocker arms.

5. Install the fuel injection pump (7B–16.8) and other parts removed.

6. Prime fuel injection system.

N–02456

Fig. 7B–202 Removing Flywheel 7B–26.3 Crankshaft Removal 1. Remove the cylinder heads, pistons and rods.

2. Remove the front cover (See Section 7B–23) and crankshaft gear.

3. Remove oil pan and oil pump.

4. Remove the flywheel and end cover (Fig. 7B–202). Discard the bolts.

5. Remove the bolt from the center main bearing. Remove the crankshaft from the block.

PI–01988

6. Remove the center main bearing from the crankshaft (Fig. 7B–203).

(Deutz F2L511) –7B–38–

Fig. 7B–203 Removing Center Main Bearing 630, 631, 632 Loader Service Manual

7B–26.4 Crankshaft Inspection Clean all parts and check for wear or damage.

1. Check the crankshaft. Replace (or have it ground) if necessary (See Section 8 for specifications).

PI–02066

Fig. 7B–204 Installing Bearing 2. Install the correct bearing shell in the center main bearing.

3. Check the thrust washers for wear and damage (See Section 8 for specifications).

N–02458

7B–26.5 Crankshaft Assembly

Fig. 7B–205 Installing Thrust Washer

1. Install the correct bushings into the block and end plate. The oil holes in the bushings must be in alignment with the holes in the block and end plate (Fig. 7B–204).

NOTE: The bearing will be extended .055–.067 (1,4–1,7 mm) outside the front of the block.

N–02459

Fig. 7B–206 Bearing Support Marks 2. Put grease on the thrust washer in the crankcase to hold it in position. The tab on the washer must align with the slot (Fig. 7B–205).

3. Install the bearings of the correct size in the center bearing support and install the support on the crankshaft. The numbers on the support must be matched (Fig. 7B–206).

4. Put the crankshaft in the block. Do not damage the bushing in the block during installation. The hole in the bearing support must be in alignment with the holes in the block (Fig. 7B–207).

(Deutz F2L511) –7B–39–

PI–01983

Fig. 7B–207 Installing Crankshaft 630, 631, 632 Loader Service Manual

5. Install the thrustwasher, seal and gasket in the end plate. The hole in the block must be in alignment with the hole in the plate. Put the plate in position and install 2 bolts (Fig. 7B–208).

6. Measure the end play of the crankshaft (Fig. 7B–209). If the movement is not within the specification, install (or remove) paper gaskets as needed to get correct clearance.

N–02460

Fig. 7B–208 Installing End Plate 7. Tighten all bolts in the end plate and the bolt in the main bearing support.

Check the crankshaft. The gear must fit on the locating pin in the crankshaft and the timing marks must be aligned.

7B–27 FLYWHEEL The ring gear for the starter is removed with a hammer and blunt punch (Fig. 7B–211).

N–02461

To install the new gear, heat the ring to (200°C) and install onto a cool flywheel.

Fig. 7B–209 Checking End Play

Installing Flywheel 1. Use new bolts (4) (Do not re–use old bolts).

N–02462

2. Tighten to 22 ft.–lbs. (30 Nm) torque. Then 60° + 60° diagonally.

Fig. 7B–210 Aligning Timing Marks

Sealing Rings 7B–28 ENGINE OIL COOLER Use new sealing rings on the banjo bolt (Fig. 7B–212).

PI–02042

Fig. 7B–211 Removing Ring Gear Revised Mar. 85

(Deutz F2L511) –7B–40–

B–03539

Fig. 7B–212 Fitting Oil Cooler 630, 631, 632 Loader Service Manual

ENGINE SERVICE (FORD ENGINE–632) Paragraph Number CAMSHAFT AND VALVE LIFTERS . . . . . . . . . . . . . . . . . .

CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBURETOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . .

CONNECTING ROD BEARINGS . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT REAR OIL SEAL . . . . . . . . . . . . . . . . . . . .

CYLINDERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE DIAGNOSIS & TESTING . . . . . . . . . . . . . . . . . . .

ENGINE FRONT COVER, TIMING CHAIN & CRANKSHAFT SPROCKETS . . . . . . . . . . . . .

ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FLYWHEEL RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAIN BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PUMP, INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PUMP, REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . .

TIMING CHAIN TIGHTENER . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE PUSHROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE ROCKER ARM COVER, ROCKER ARM AND/OR SHAFT . . . . . . . . . . . . . . . . . . .

VALVE SPRING, RETAINER AND STEM SEAL (CYLINDER HEAD INSTALLED) . . . . . . . . . . . . . .

VALVE SPRING, RETAINER AND STEM SEAL (CYLINDER HEAD REMOVED) . . . . . . . . . . . . . .

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page Number

7C–18 7C–27 7C–3 7C–2 7C–24 7C–26 7C–22 7C–11 7C–4

7C–23 7C–30 7C–9 7C–2 7C–27 7C–29 7C–26 7C–18 7C–9

7C–15 7C–5 7C–7 7C–19 7C–16 7C–10 7C–23 7C–20 7C–6 7C–21 7C–25 7C–17 7C–1 7C–9

7C–21 7C–10 7C–16 7C–25 7C–23 7C–18 7C–26 7C–25 7C–16 7C–26 7C–27 7C–23 7C–1 7C–17

7C–8

7C–17

7C–13

7C–20

7C–12 7C–14

7C–20 7C–21

FORD (632)

–7C––1–

630, 631, 632 Loader Service Manual

–7C–0–

630, 631, 632 Loader Service Manual

7C ENGINE SERVICE (Ford Engine) 632 7C–1 TROUBLESHOOTING The following troubleshooting chart is provided as an aid in locating and correcting loader problems which are most common. Many of the recommended corrective actions must be accomplished by authorized Bobcat servicing personnel only and should not be attempted by owner/operator personnel. Follow safety rules, front page!

TROUBLESHOOTING THE ENGINE PROBLEM Starter will not turn engine.

Engine does not start or is difficult to start.

CAUSE

CORRECTION

Battery has lost its charge.

Charge battery. Check the function of charging system.

Loose battery connection.

Clean battery connections and cables. Tighten the clamps.

Loose starter connections.

Tighten the connections.

Starter switch has defect.

Make replacement of switch.

Fuse has burned out.

Install new fuse of correct amp. rating.

Broken or disconnected wiring harness.

Connect or make replacement of wiring.

Starter or solenoid has defect.

Make repair as needed.

Wrong starting procedure.

Refer to “Starting Procedure” in the Bobcat Owner’s Manual.

No fuel in tank.

Add fuel.

Broken wire to the fuel shut–off solenoid.

Make repairs as needed.

Air cleaner is dirty.

Make replacement of air cleaner element.

Fuel tank vent in cap has restriction.

Remove the cap and clean vent.

Fuel line has air leak or dirt, or water.

Correct as required.

Fuel pump has defect.

Make replacement of pump.

Hydraulic/hydrostatic engine.

load

on

Put all controls in neutral position and warm oil reservoir during very low temperatures.

Ignition system has defect.

Check and make repairs as needed.

Crankcase oil is thick.

Use engine oil of correct viscosity, (See Oil Specification Chart).

–7C–1–

630, 631, 632 Loader Service Manual

PROBLEM

CAUSE

Engine runs rough or engine stops.

Faulty ignition system (spark plugs, points, etc.) or incorrect timing.

Make repairs as necessary.

Dirty fuel mixture, or restriction in fuel filter or vent.

Clean as necessary.

Poor compression.

Check for loose cylinder head screws or loose spark plugs.

Water in fuel.

Make replacement of fuel.

Engine is overloaded.

Operate at rated RPM.

Radiator grill is dirty.

Remove grill and clean.

Dirty engine oil.

Make replacement of engine oil and filter.

Exhaust system has restriction.

Correct as necessary.

Injection timing is wrong.

Make adjustment as necessary.

Coolant level is low.

Add coolant.

Oil cooler has restriction.

Find restriction correction.

Engine overheats.

7C–2 CHECKS AND ADJUSTMENTS 7C–2.1 Engine Oil Pressure Engine oil pressure is good if the red warning light on the instrument panel is not illuminated. To check operation of warning light, turn ignition switch on. The warning light must be illuminated.

CORRECTION

Valve In The Down Position #8 #7 #6 #5 #4 #3 #2 #1

and

make

Make Adjustment To This Valve #1 #2 #3 #4 #5 #6 #7 #8

Fig. 7C–12 Valve Adjustment Chart

Feeler Gauge

7C–2.2 Valve Clearance (Fig. 7C–1) Make adjustment of valve clearance with the engine stopped.

When No. 8 valve is in the down position then No. 1 valve is in the correct position for the clearance to be set (See Fig. 7C–2 for the valve position).

Put a feeler gauge between rocker arm and pushrod and turn adjustment screw in or out to get the correct clearance.

(See Section 8 “TECHNICAL DATA” for correct clearance.)

A–02500

Fig. 7C–1 Valve Adjustment –7C–2–

630, 631, 632 Loader Service Manual

7C–2.3 Checking Compression

Engine

1. Be sure crankcase oil is at correct level and the battery has full charge. Run the engine for 30 minutes at 1200 RPM or until the engine is at normal operating temperature. Turn the ignition switch off. Remove all the spark plugs and remove coil wire from center of distributor cap.

2. Push the throttle lever all the way to “fast” position and set the choke so that the choke plate is open.

3. Install a compression gauge in number 1 cylinder.

4. Turn the engine over at least 5 compression strokes and record the highest reading. Remember the approximate number of strokes needed to get the highest reading.

5. Repeat this test on each cylinder, but instead of turning the engine 5 strokes, use the number of strokes needed to get the highest reading for number 1 cylinder.

Understanding the Results of the Test If the lowest reading is at least 75% of the highest, the compression is normal (See Chart on this page).

EXAMPLE: Seventy–five percent of 140 psi (the highest compression reading) is 105 psi.

Maximum

Minimum PSI 101 102 104 105 107 108 110 111 113 114 115 117 118 120 121 123 124 126 127 129 131 132 133 135 136 138 140 141 142 144 145 147 148 150 151 153 154 156 157 158 160 162 163 165 166 168 169 171 172 174 175 177 178 180 181 183 184 186 187

PSI 134 136 138 140 142 144 146 148 150 152 154 156 158 160 162 164 166 168 170 172 174 176 178 180 182 184 186 188 190 192 194 196 198 200 202 204 206 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250

If the lowest reading is NOT 75% of the highest, this can be an indication of bad valves or valve seats, worn or broken piston rings.

–7C–3–

630, 631, 632 Loader Service Manual

If one, or more, cylinders have a low reading, put .50 oz. (0,014 kg) of engine oil on top of the pistons in the cylinder with low readings. Repeat compression check on these cylinders.

1. If compression gets better, the piston rings are bad.

2. If compression does not improve, the valves are not operating correctly or the valve or valve seats are worn.

3. If two cylinders next to each other have low compression readings and putting oil on the pistons does not increase the compression, the cause can be the cylinder head gasket. The gasket can have a leak between the cylinders.

B–02662

Fig. 7C–3 Removing Belt Shield

NOTE: DO NOT operate engine with this condition.

This condition can let engine oil or engine coolant into the cylinder and cause damage to the engine.

1/2” Movement

1/4” Movement

7C–2.4 Carburetor, Throttle Governor Adjustments

and

1. Put blocks under the frame of the Bobcat so that there is no danger of the machine falling and causing personal injury.

B–02661

2. Remove belt shield (Fig. 7C–3).

Fig. 7C–4

3. Loosen governor fastening bolts and make adjustment of belt to give 1/4 inch (6,35 mm) freeplay (Fig. 7C–4). Tighten governor fastening bolts.

Belt Tension Adjustment

Throttle Rod

4. Install belt shield.

1 NOTE: If only belt needs adjustment, make adjustment to linkage (Item 1).

5. Disconnect jackshaft–to–governor (Fig. 7C–5, Item 1).

throttle linkage

6. Remove the throttle linkage from the governor control arm (Fig. 7C–5, Item 2).

2 Governor Control Arm B–02409

Fig. 7C–5 Throttle/GovernorAdjustment –7C–4–

630, 631, 632 Loader Service Manual

7. Make adjustment between the governor and carburetor linkage so that the distance between pivot points is 4–7/8 inches (123,8 mm) (Fig. 8C–6).

8. Check to see that there is free movement of the throttle plate in carburetor.

4–7/8” (123,8 mm) 9. Install linkage on governor control arm.

A–02503

Fig. 7C–6 Linkage Adjustment 10. Loosen control arm stop until it has no effect on governor control arm (Fig. 7C–7).

11. Loosen the two screws on the governor control arm (Fig. 7C–8).

12. Move the governor control arm and control arm–to–carburetor linkage as shown in figure 7C–8.

Control Arm Stop

13. Hold the control arm and linkage in this position and tighten the two screws.

Move Control Arm This Way

14. Start the engine and turn idle screw on the carburetor to set the engine speed at 800 RPM (Fig. 7C–9).

15. Set the correct ignition timing.

(See 7C–2.7 “Ignition Timing” for correct procedure.)

Throttle Linkage B–02400

Fig. 7C–7 Control Arm Stop

B–02320

Fig. 7C–8 Control Arm Adjustment

16. Set the throttle lever in slow position.

17. Hold the governor control arm all the way as shown in figure 7C–8, then make adjustment to throttle linkage until the pin goes exactly into the hole in the throttle jackshaft.

Idle Adjustment Needle 18. Start engine and set throttle lever (inside ROPS on right side of seat) at fast idle. Make adjustment to stop bolt until engine runs at 2600–2675 RPM. 19. Turn control arm stop (Fig. 7C–7) until there is an increase of 25 RPM.

Throttle Idle Adjustment

B–02409a

Fig. 7C–9

Carburetor Adjustment

–7C–5–

630, 631, 632 Loader Service Manual

NOTE: Make sure to check the governor oil level by removing the plug (Fig. 7C–10). If oil flows out, level is good. If no oil flows out, add SAE 10W/30 or 10W/40 oil until it flows from the check plug port. Install the plug.

7C–2.5 Ignition System Coil to Coil Ground Voltmeter Test 1. Connect the voltmeter wires as shown in figure 7C–11.

2. Operate starter until breaker points are closed.

3. Turn all lights and accessories off.

Check/Fill Plug

4. Turn the ignition switch on.

5. If the voltmeter reading is 0.25 volt or less, the primary circuit from coil to ground is good.

B–02734

6. If the voltmeter reading is more than 0.25 volt, test the voltage loss between each of the following:

Fig. 7C–10 Governor Oil Check

a. The connector marked “DIST” on the coil and the connection on the distributor. b. The moving breaker point and the stationery breaker point. c. The breaker point and the distributor housing. d. The distributor housing and the engine ground.

Rotunda RE–16–31 or RE–27–44 Tester

If voltage loss of all above has a total of more than 0.25 volt, it will cause poor engine performance.

BLACK

Spark Plug Wires Resistance Test These wires include the wires connecting the distributor cap to the spark plug and the wire connecting the center connection of the distributor cap to the center connection of the ignition coil.

These wires are the radio resistance–type. The resistance of each wire must not be more than 5000 ohms per inch (25,4 mm). When checking the resistance of the wires or setting ignition timing, do not puncture the wires. This can cause a separation in the conductor.

B D Red

PI–02143

Fig. 7C–11 Coil–To–Ground Test

Spark Plug Test Inspect and clean the electrodes and make adjustment of the spark plug gap. After the gap is correct, check the plugs on the testing machine. Compare the operation of the reconditioned plug with a new plug.

Distributor Tests 1. Disconnect the distributor primary wire on the coil. Connect a short jumper wire to the “DIST” connection of the coil and the distributor primary wire.

Connect the red wire to the jumper wire.

2. Connect the block wire to a good ground on the engine.

Dwell Angle Check 1. Connect the tester.

2. Turn the test control knob to the set position.

3. Adjust the set control knob until the needle on the dwell meter lines up with the set line.

4. Start the engine and let it idle.

–7C–6–

630, 631, 632 Loader Service Manual

5. Turn the cylinder selector to the four.

6. Read the dwell angle on the dwell meter and compare the reading to specifications in Section 8 “TECHNICAL DATE”.

7. Turn off the engine.

8. If the dwell angle was below the specified amount, the breaker point gap is wide. If the dwell angle was above the specified amount, the breaker point gap is narrow.

If the dwell is at specifications, turn the test selector knob to the OFF position and disconnect the tester leads and jumper wire.

Make adjustment of points as necessary.

Spark Strength Tests Locating Trouble 1. Remove the coil high voltage wire from the distributor cap.

2. Turn on the ignition switch.

3. While holding the high tension lead about 3/16 inch from the cylinder head or any other good ground, turn the engine. If the spark is good, the trouble is in the secondary circuit (spark plugs, wires, etc.).

If there is no spark, the trouble is in the primary circuit, coil to distributor wire, or the coil.

7C–2.6 Ignition System Tests Battery to Coil Voltmeter Test 1. Connect the voltmeter wires as shown in figure 7C–12.

2. Connect a jumper wire to the distributor connection of the coil and to a good ground on the distributor housing.

3. Turn the lights and accessories off.

4. Turn the ignition switch on.

5. If the voltmeter reading is between 4.5 and 6.9 volts, the primary circuit from the battery to the coil is good.

Red

6. If the voltmeter reading is greater than 6.9 volts, check the following: The battery and cables for loose connections or corrosion.

Rotunda RE 16–31 or RE–27–44 Tester

Primary Wire From Switch to ”B” TERMINAL

The primary insulation, broken wires, and loose or corroded connections.

Check the starter–relay–to–ignition switch for damage.

Red

Dist.

+

Starting Ignition Circuit Voltmeter Test 1. Connect the voltmeter leads as shown in figure 7C–11.

2. Disconnect and ground the coil to distributor high voltage wire at the distributor.

Black PI–02144

Fig. 7C–12 Coil To Battery Test –7C–7–

630, 631, 632 Loader Service Manual

3. With the ignition switch off, turn the engine with an auxiliary starter switch while reading the voltage loss.

CONDENSER

STATIONARY CONTACT

4 LOBE CAM BREAKER ARM CONTACT

4. If the voltage loss is 0.4 volt or less, the starting ignition circuit is good.

RETAINING SCREW

RETAINING SCREW

5. If the voltage loss is greater than 0.4 volt, clean and tighten the connections in the circuit or make replacement of the wiring as necessary.

RUBBING BLOCK PI–02145

Fig. 7C–13 Point Gap Adjustment Breaker Point Gap Adjustment 1. Turn the engine until the rubbing block is on the high point of the cam lobe.

Insert the correct thickness blade of a clean feeler gauge between the breaker points (Fig. 7C–13). Make adjustment of the points to correct gap and tighten the screws.

Clean the cam area, then put a light film cam lubricant on the cam when new points are installed. Do not use engine oil as lubricant.

7C–2.7 Ignition Timing Timing Mark Locations The timing marks and their locations are shown in figure 7C–14.

Initial Ignition Timing 1. Disconnect vacuum advance hose from distributor and put plug in hose.

2. Clean and mark the specified timing mark with chalk or white paint.

3. Connect a timing light to the No. 1 cylinder spark plug wire. Connect a tachometer to the engine.

4. Start the engine and decrease the idle speed to 600 RPM to be sure that the centrifugal advance is not operating. Make adjustment of the initial ignition timing to 12° by loosening clamp and rotating the distributor in the correct direction.

5. Check the centrifugal advance for correct operation by starting the engine and running it at 2000 RPM. If the ignition timing advances, the centrifugal advance mechanism is operating correctly. Note the engine speed when the advance starts and the amount of total advance. Stop the engine.

6. Connect vacuum hose.

TIMING MARK SKETCH

CYLINDER AND DISTRIBUTOR NUMBERING

ROTATION

USE FIRST NOTCH IN PULLEY BTDC

FRONT

CAP CLIP POSITION

TDC DISTRIBUTOR POSITION

FIRING ORDER–1–2–3–4

VIEWED FROM LEFT SIDE OF ENGINE

Fig. 7C–14

COUNTERCLOCKWISE

Timing Marks

–7C–8–

630, 631, 632 Loader Service Manual

7B–3 CARBURETOR REPAIR (Fig. 7C–15) 1. Remove four bowl–to–body screw and lockwasher assemblies (1).

2. Remove throttle body and gasket (2) from fuel body. Be careful not to cause damage to float assembly.

Throttle Body

3. Put screwdriver against float axle (3) at slotted side of float hinge and push axle through slotted side of bracket. Remove axle from opposite side of hinge and remove float assembly (4).

4 3 7 6

4. Remove fuel valve needle (5), valve seat (6) and fiber washer (7).

5 2

5. Use new parts in repair kit to make replacement of above parts.

Solenoid 1

If parts other than those included in repair kit need replacement, make replacement of carburetor assembly.

7C–4 ENGINE DIAGNOSIS AND TESTING Camshaft Lobe Lift Check the lift of each lobe and make a note of the readings.

1. Remove the rocker cover.

2. Remove the assembly.

rocker

Fuel Body shaft B–02570R

Fig. 7C–15 Carburetor Assembly

3. Make sure the pushrod is in the valve lifter socket. Install a dial indicator so that the ball socket adapter of the indicator is on the end of the pushrod and in the same plane as the pushrod movement (Fig. 7C–16).

4. Turn the crankshaft over until the lifter is in its lowest position.

5. Set the dial indicator at zero. Continue to rotate the crankshaft slowly until the pushrod is in the highest position (highest indicator reading).

DIAL INDICATOR

6. Compare the total reading on the indicator with specifications.

7. To check the accuracy of the original indicator reading, continue to rotate the crankshaft until the indicator reads zero. If the reading on any lobe is below specified wear limits, the camshaft and the valve lifters must have replacement.

8. Remove the dial indicator 9. Install the rocker shaft assembly.

10. Install the rocker cover.

PI–02147

Fig. 7C–16 –7C–9–

Checking Camshaft Lift

630, 631, 632 Loader Service Manual

7C–4.1 Crankshaft End Play 1. Push the crankshaft toward the rear (flywheel end) of the engine.

2. Install a dial indicator to zero so that the contact point is against crankshaft flange at front of engine and the indicator is parallel to the crankshaft (Fig. 7C–17).

3. Set the dial indicator to zero. Push the crankshaft forward and note the reading on the dial.

4. If the end play is more than the wear limit (in specifications), install new thrust washers. If the end play is less than the minimum limit, inspect the thrust bearing faces for scratches, rough areas or dirt.

Tool–6565

Fig. 7C–17

Tool–4201–C

PI–02148

Checking Crankshaft End Play

7C–4.2 Flywheel Face Alignment Check 1. Push the crankshaft fully forward or toward the rear.

2. Install a dial indicator so that the indicator point is against the flywheel face.

3. Set the dial indicator to zero and turn the crankshaft and check the indicator reading.

4. If alignment is not to specification, remove flywheel and check for dirt or other foreign material between the flywheel and crankshaft flange. If alignment is not to specifications, install new flywheel or grind crankshaft or flywheel as necessary to correct alignment.

7C–4.3 Camshaft End Play 1. Push the camshaft toward the rear (flywheel end) of the engine.

2. Install a dial indicator so that the indicator point is on the hub of the camshaft sprocket.

3. Set the dial indicator to zero.

4. Put a large screwdriver between the camshaft sprocket and the cylinder head. Pull the camshaft forward and release it.

5. Check the indicator reading. If reading is more than specification, make replacement of the thrust plate that holds the camshaft.

7C–5 ENGINE OVERHAUL 7C–5.1 Cylinder Head Do not grind more than 0.010 (0,254 mm) inch from the cylinder head gasket surface. Remove all rough edges or scratches with an oil stone.

7C–5.2 Valve Guides If the valve guides become badly worn, it will be necessary to install valves with an oversize stem.

Valves with oversize stems are available in the following oversize amounts: .003 inches .015 inches .030 inches Use correct reamer to make valve guides larger.

–7C–10–

630, 631, 632 Loader Service Manual

When going from a standard size valve to an oversize valve, always use the reamer in sequence. Grind the valve seat after the valve guide has been cut, and use a sharp tool to break the sharp corner (ID) at the top of the valve guide.

TO REMOVE STOCK FROM TOP OF SEAT, USE 30° WHEEL 45°

7C–5.3 Grinding Valve Seats (Fig. 7C–18) The valve seats are a part of the cylinder head. If the valve seats become burned so that the valves and seats are not in correct contact grinding the valve seats is necessary.

VALVE SEAT WIDTH

Grind both intake and exhaust valve seats at 45°. Grind only enough to give a smooth surface.

Make the valve seat the correct width. (See Specifications.) Use a 60° grinding wheel to remove material from the bottom of seat and a 30° grinding wheel for the top. The finished valve seat must be in contact at approximately the center of the valve face.

TO REMOVE STOCK FROM BOTTOM OF SEAT, USE 60° WHEEL

PI–02150

Fig. 7C–18

Grinding Valve Seat

7C–5.4 Valves Small burns, grooves, etc., can be removed. Remove valves that are badly damaged, if the face alignment cannot be corrected by finishing or stem clearance is more then specifications.

Grinding Valves If the valve face alignment is not within specifications and/or to remove burns and grooves, grind the valve to a 44 degree angle. Remove only enough material to correct the alignment or to make a smooth surface. If the edge of the valve head is less than 1/32 inch thick after grinding (Fig. 7C–16), install new valve as the old valve will cause engine to run hot. Remove all grooves or scratch marks from the end of the valve stem, and make chamfer as necessary. Do not remove more than 0.010 inch (0,245 mm) from the end of the valve stem.

If the valve and/or valve seat has been finished, it will be necessary to check the clearance between the rocker arm and the valve stem with the rocker assembly installed in the engine.

7C–5.5 Select Fitting of Valves If the valve stem to valve guide clearance is more than the wear limit, use a reamer to cut the valve guide for the next oversize valve stem. Valves with oversize stem diameters of 0.003, 0.015 and .030 inch are available for service. Grind the valve seat after the valve guide has been out.

7C–5.6 Camshaft Repair Remove small mark (scores or scratches), from the camshaft machined surfaces with a smooth oil stone.

7C–5.7 Crankshaft Remove small scores with an oil stone. If the journals are damaged or worn, they must be machined to correct size for the next small size bearing.

7C–5.8 Reconditioning Crankshaft Journals After machining the bearing surfaces, put chamfer in the oil holes; then finish the bearing surfaces with a No. 320 grit cloth and engine oil. Crocus cloth may also be used for finishing.

7C–5.9 To Check Crankshaft or Connecting Rod Bearings With Plastigage 1. Clean crankshaft bearing surfaces. Inspect bearing surfaces and thrust faces (thrust bearing) for damage. When making replacement of standard size bearings, install bearing of minimum specified clearance. If the desired clearance cannot be made with a standard bearing, use a 0.002 inch smaller size in combination with a standard bearing to get the correct clearance (See Section 8, “Technical Data”.

–7C–11–

630, 631, 632 Loader Service Manual

2. Put a piece of Plastigage on bearing surface across full width of bearing cap and about 1/4 inch (6,35 mm) off center (Fig. 7C–19).

3. Install cap and tighten bolts to correct torque. Do not turn crankshaft while Plastigage is in place.

PLACE PLASTIGAGE FULL WIDTH OF JOURNAL ABOUT 1/4 INCH OFF CENTER

CHECK WIDTH OF PLASTIGAGE

4. Remove cap. Using Plastigage scale, check width of Plastigage at widest point to get minimum clearance. Check at narrowest point to get maximum clearance. Difference between readings is taper of bearing surfaces.

5. If clearance is more than specified limits, on the connecting rod bearings, use a 0.002 inch smaller size bearing in combination with the standard bearings. Bearing clearance must be within specified limits. If 0.002 smaller size main bearings are used on more than one bearing surface, be sure they are installed in cylinder block side of bearing. If standard and 0.002 inch smaller size bearings do not make clearance within desired limits, machine the crankshaft bearing surface, then install smaller size bearings.

6. After bearing has been checked, remove Plastigage, put a light coat of engine oil on the bearing surface and bearings. Install bearing cap. Tighten cap bolts to correct torque.

7. Do the above for all bearings that need replacement.

INSTALLING PLASTIGAGE

0.0015” CLEARANCE

MEASURING PLASTIGAGE

PI–02153

Fig. 7C–19 Installing/Measuring

Plastigage

7C–5.10 Pistons, Pins and Rings To Install Pistons Pistons are available for service in standard sizes and oversizes.

NOTE: When the piston is replaced, make sure the marking (FRONT) on the piston and the connecting rod are both on the same side.

The standard size pistons are color coded red or blue, or have .0025 O.S. marked on the top. Refer to SEction 8 “Technical Data” for standard size piston dimensions.

Measure the piston diameter to be sure that the specified clearance is made.

When a new piston has been checked for clearance, mark it for assembly in the cylinder to which it was checked. If the taper, out–of–round and piston to cylinder bore clearance conditions of the cylinder bore are within specified limits, new piston rings will give good service. If new rings are to be installed in a used cylinder that has not been finished, remove the cylinder wall glaze with a hone. Be sure to clean the cylinder bore thoroughly after honing.

NOTE: Make sure when installing the piston in the block that the arrow is toward the front of the engine (Fig. 7C–20).

1. Find the size piston to be used by making a cylinder bore check.

B–03740

Fig. 7C–20 Installing The Pistons

2. Find the correct size piston to give the correct clearance (Refer to Section 8 “Technical DATA”). Measure the piston 2–1/4 inch (57,15 mm) below the top and at 90° to the piston pin bore.

3. Make sure the piston and cylinder block are at room temperature (70 degrees F. (21,1 degrees C.). After any finishing operation let the cylinder bore cool and make sure the piston and bore are clean and dry before the piston fit is checked.

To Install Piston Rings The piston rings use two compression rings and one oil control ring. The lower compression ring is stepped on the bottom outer edge and the upper ring is chrome plated and tapered on the outside diameter. Both rings are marked top and must be installed correctly. The upper ring, when new, has a red–brown compound on the outer edge. This compound must not be removed. The oil control rings have narrow ring cases and can be installed either way.

1. Use the correct ring set for the size of cylinder bore.

2. Put the ring in the cylinder bore in which it is going to be used.

3. Use the head of a piston to push the ring in the bore about 1 inch (25,4 mm) so that the ring is square with the cylinder wall. Use caution to prevent damage to the ring or cylinder bore.

–7C–12–

PI–02154

Fig. 7C–21 Checking Gap Of Piston Ring 630, 631, 632 Loader Service Manual

4. Measure the gap between the ends of the ring with a feeler gauge (Fig. 7C–21). If the ring gap is less or greater than the specified limits, use another ring set.

5. Check the side clearance of the compression rings with a feeler gauge inserted between the ring and its lower edge (Fig. 7C–22). The gauge must slide freely around the entire ring circumference. If the grooves are worn, make replacement of piston.

Installing Piston Pins Pistons and piston pins are available as a unit only and can not be purchased as individual items. Keep correct pins and pistons together.

PI–02155

Valve Rocker Arm and/or Shaft Assembly

Fig. 7C–22

Checking Side Clearance

Use a hone to remove minor surfaces defects on the rocker arm shaft and in the rocker arm bore.

If the valve end of the rocker arm has a grooved radius, make replacement of the rocker arm. Do not grind this surface.

Push Rods Check the push rods for straightness.

If alignment is off more than the maximum limit at any point, do not use the pushrod. Do not straighten pushrods.

7C–5.11 Cylinder Block Finishing Cylinder Walls Before any cylinder is machined, all main bearing caps must be in place and tightened to the correct torque. Finish only the cylinder or cylinders that need it.

All pistons are the same weight, both standard and oversize; and various sizes of pistons can be used without changing the engine balance. Finish the cylinder with the most wear first to find the maximum oversize. Finish the cylinder to within 0.0015 inch (.038 mm) of the oversize diameter. This will leave enough material for the final step of honing for correct surface finish and pattern. Use a motor–driven, spring pressure–type hone at a speed of 300–500 RPM and hoses of grit sizes180–220. Use a lubricant mixture of equal parts of kerosene and SAE No. 20 motor oil.

7C–5.12 Cylinder Head Cleaning With the valves installed to protect the valve seats, remove deposits from the combustion chambers and valve heads with a scraper and a wire brush. Be careful not to damage the cylinder head gasket surface. Remove the valves and clean the valve guide bores with a valve guide cleaning tool. Use cleaning solvent to remove grease and other deposits. Clean all bolt holes. Remove all deposits from the valves with a fine wire brush or buffing wheel.

Inspection Check the cylinder head for cracks and inspect the gasket surface for foreign material and scratches.

When a cylinder head is removed because of gasket leaks, check the flat area of the cylinder head gasket surface for correct specifications. If necessary to finish the cylinder head gasket surface, do not machine off more than 0.010 inch (0,254 mm).

Check the valve seat with a gauge. If wear is beyond limits, grind the valve and valve seat. Measure the valve seat width. Grind valve seat when width is not within specifications.

Inspect the valve face and the edge of the valve head for damage. Inspect the stem for a bent condition and the end of the valve stem for wear.

–7C–13–

630, 631, 632 Loader Service Manual

Check the valve stem to valve guide clearance of each valve in its respective valve guide.

Check the springs for correct pressure at the specified spring lengths (Tool 6513–DD). Make replacement of any springs not within specifications.

Check each spring for squareness, using a steel square and a flat surface. Put the spring and square on end on the flat surface. Slide the spring up to the square.

Turn the spring slowly and check the space between the top coil of the spring and the square. The out–of–square limits are 0.078 inch (1,98 mm).

Follow the same procedure to check new valve springs before installation. Make sure the correct spring (color coded) is installed.

7C–5.13 Tappets Cleaning Thoroughly clean the tappets in cleaning solvent and wipe them with a clean lint–free cloth.

Inspection Check the tappets for wear or damage. Check the bottom end of tappet to make sure that it has a slight convex. Make replacement of tappets that are damaged, worn, or if the bottom is not smooth. If the bottom surface is worn flat, it can be used with the original camshaft only.

7C–5.14 Camshaft Cleaning and Inspection Clean the camshaft in solvent and wipe it dry. Inspect the camshaft lobes for damage and wear. The camshaft does not need replacement unless the lobe lift is worn more than 0.005 inch (0,127 mm).

The lift of the camshaft lobes can be checked with the camshaft installed in the engine or on centers. Refer to 7C–4 “Camshaft Lobe Lift”.

7C–5.15 Crankshaft Inspection Measure the diameter of each journal in at least four places to look for out–of–round, taper or smaller size conditions.

7C–5.16 Flywheel Inspection Inspect the flywheel for cracks, or other damage.

Inspect the ring gear for wear and damage to teeth. If the teeth have damage, install new ring gear.

With the flywheel installed on the crankshaft, check the flywheel face alignment.

7C–5.17 Connecting Rods Cleaning Remove the bearings from the rod and cap. Make an identification of the bearings if they are to be used again. Clean the connecting rod in solvent, including the rod bore and under the bearings. Clean all passages with compress air (low pressure).

–7C–14–

630, 631, 632 Loader Service Manual

Inspection Inspect the connecting rod bearing bores for out–of–round and taper. Check the inside diameter of the connecting rod piston pin bore. If the pin bore in the connecting rod is larger than specifications, install a 0.002 inch oversize piston pin.

First, fit the oversize piston pin to the piston pin bore by using a reamer tool. When assembling the connecting rod and piston, make sure the arrow is forward and the rod has the word “Front” on the web, both must be in the same direction (Fig. 7C–23), piston, piston pin and connecting rod.

7C–5.18 Pistons, Pins and Rings Cleaning Remove deposits from the piston surfaces. Clean deposits from the piston skirt, piston pins and rings with solvent.

Clean the ring grooves with a ring groove cleaner. Make sure the oil ring slots (or holes) are clean.

A–02746

Inspection Fig. 7C–23

Assembling Piston & Rod

Replace pistons that show signs of over maximum wear or damage.

Check the piston to cylinder bore clearance by measuring the piston and bore diameters. Refer to the specifications for correct clearance. Refer to 7C–5.20 “Cylinder Block Inspection” for the bore measurement procedure. Measure the outside diameter of the piston with micrometers about 2–1/4 inches (57,15 mm) below the dome and at 90 degrees to the piston pin bore. Check the ring side clearance. See 7C–5.10 “Pistons, Pins and Rings”.

Check the outside diameter of the piston pin and the inside diameter of the pin bore in the piston. Make replacement of any piston pin or piston that is not within specifications.

Replace all rings that have damage. Check the end gap and side clearance. Rings must not be removed from one piston and installed on another.

7C–5.19 Main and Connecting Rod Bearings NOTE: Main bearings have color codes; to identify size. See Section 8, “Technical Data”.

Cleaning Clean the bearing inserts and caps thoroughly in solvent, and dry them with compressed air. Do not scrape deposits from the bearing shells.

Inspection Inspect each bearing carefully. Bearings that have a damage or much wear need replacement. Check the clearance of bearings that look good with Plastigage (7C–5.9 “Main and Connecting Rod Bearings”).

7C–5.20 Cylinder Block Cleaning After any cylinder bore repair operation, clean the bore(s) with soap and water.

Then, thoroughly rinse the bore(s) with clean water to remove the soap, and wipe the bore(s) with a clean cloth with engine oil on it.

If the engine is disassembled, thoroughly clean the block with solvent. Remove old gasket material from all machined surfaces. Remove all pipes plugs that seal oil passages; then clean all the passages. Clean all passages, both holes, etc., with compressed air. Make sure the threads in the cylinder head bolt holes are clean. Use a tap to clean the threads and to remove any deposits. Thoroughly clean the grooves in the crankshaft bearing and bearing retainers.

–7C–15–

630, 631, 632 Loader Service Manual

Inspection Inspect the cylinder walls for damage, or other signs of wear.

Check the cylinder bore for out–of–round and taper. Measure the diameter of each cylinder bore at the top, center and bottom with the gauge placed at right angles and parallel to the centerline of the engine. Use only the measurements at 90 degrees t the engine centerline when calculating the piston to cylinder bore clearance.

FEELER GAUGE

N–02164

Machine cylinders that are damaged or when out–of–round and/or taper or more than the wear limits.

Fig. 7C–24 Checking Outer Race To housing Clearance

7C–6 OIL PUMP FEELER GAUGE

7C–6.1 Cleaning Wash all parts in a solvent and dry them thoroughly with compressed air. Use a brush to clean the inside of the pump housing and the pressure relief valve chamber. Be sure all dirt and metal particles are removed.

7C–6.2 Inspection Check the inside of the pump housing and the outer race and rotor for damage or wear.

N–02165

Fig. 7C–25

Measure the outer race to housing clearance (Fig. 7C–24). Check the clearance between the outer race and the rotor lobes (Fig. 7C–25).

Checking Rotor Lobes–To–Race Clearance

STRAIGHT EDGE

With the rotor assembly installed in the housing, place a straight edge over the rotor assembly and the housing. Measure the clearance (rotor end play) between the straight edge and the rotor (Fig. 7C–26). The outer race, shaft and rotor can have replacement only as an assembly.

Check the drive shaft to housing FEELER bearing clearance by measuring the GAUGE outside diameter of the shaft and the Fig. 7C–26 Checking Rotor End Play inside diameter of the housing bearing. Inspect the relief valve spring for condition. Check the relief valve spring tension. If the spring tension is not within specifications and/or the spring is worn or has damage, install new spring. Check the relief valve piston for damage and free operation in the bore.

N–02166

7C–7 REMOVAL OF ENGINE 1. Remove ROPS. 2. Disconnect radiator hoses.

3. Disconnect throttle and choke linkages.

4. Disconnect fuel line and air cleaner hose.

5. Disconnect wiring at connector plug.

–7C–16–

630, 631, 632 Loader Service Manual

6. Remove battery cables.

7. Remove fastening bolts from engine support plate.

8. Use a hoist to lift engine. Slide engine backward until drive coupling is disconnected from transmission (Fig. 7C–27).

9. Lift engine out through rear of Bobcat.

10. To install, reverse above steps.

7C–8 VALVE ROCKER ARM COVER, ROCKER ARM AND/OR SHAFT 7C–8.1 Removal and Disassembly 1. Disconnect the spark plug wires and remove them from the fastener on top of rocker cover.

2. Remove the rocker cover fastening screws. Remove the rocker cover and gaskets.

C–02227

Fig. 7C–27 Removing Engine 3. Remove the rocker arm shaft attaching bolts evenly and lift off the rocker arm shaft assembly (Fig. 7C–28).

4. Remove the cotter pin from one end of the shaft and pull the flat washer, crimped washer and second flat washer off the shaft. The rocker arm shaft supports, rocker arms and springs can be removed from the shaft.

5. Remove the plugs from the rocker shaft ends by drilling a hole in one plug.

Insert a long rod through the drilled plug and hit the opposite plug out of the shaft. Remove the drilled plug using same method.

6. Clean the component parts of the shaft assembly in solvent.

7C–8.2 Installation 1. Put new plugs in the ends of the rocker shaft.

2. Assemble the rocker shaft. The bolt hole in the rocker shaft support must be on the same side as the adjustment screw in the rocker shaft. The rocker arms are right and left hand, the rocker pads are inclined towards the support. Install the cotter pins with the heads upward and bend the legs to hold.

3. Put oil on the valve stem tips, rocker arm pads and the pushrod ends. Install the rocker shaft assembly on the cylinder head and put the pushrods on the adjustment screws. Install and tighten the bolts evenly. (See Section 8 for torque specifications).

4. Make adjustment of the valve clearance to specifications.

5. See that the contacting surfaces on the cylinder head and rocker cover are free from all parts of the old gasket material.

6. Put the rocker cover and gasket on the cylinder head and fasten with the screws. Tighten the screws to correct torque specifications.

PUSH ROD

ROCKER SHAFT ASSEMBLY

7. Put the spark plug wires in the rocker cover fastener and connect them to respective plugs.

7C–9 VALVE PUSHROD 7C–9.1 Removal 1. Remove the rocker shaft bolts evenly and lift off the rocker arm shaft assembly.

CYLINDER HEAD N–02167

2. Remove the pushrods from their locations and keep them in correct order.

–7C–17–

Fig. 7C–28

Removing Rocker Arm Assy

630, 631, 632 Loader Service Manual

7C–9.2 Installation 1. Put oil on both ends of the pushrods and install them in respective bores.

2. Put oil on the valve stem tips and the rocker arm pads, and install the rocker arm shaft assembly on the cylinder head, and put the pushrods on the adjustment screws. Tighten the bolts evenly to correct torque specification.

3. Make adjustment of the valve lifters to specifications.

7C–10 INTAKE MANIFOLD 7C–10.1 Removal 1. Remove coolant from the cooling system.

2. Disconnect the throttle linkage from the throttle lever on carburetor.

3. Disconnect the fuel line from the carburetor.

4. Disconnect the water outlet hose the intake manifold.

5. Connect the throttle linkage.

6. Install dipstick tube bracket to intake manifold and install fastening bolt.

7. Fill the cooling system with the correct coolant.

8. If a new manifold is to be installed, put all necessary parts on the new manifold.

7C–10.2 Installation 1. Put a water resistant sealer to both sides of new gasket around the water port and install it on the cylinder head.

2. Install the intake manifold and tighten the nuts and bolts evenly to specifications.

3. Connect the water hose to the intake manifold.

4. Connect the fuel line to the carburetor.

5. Connect the throttle linkage.

6. Install dipstick tube bracket to intake manifold and install fastening bolt.

7. Fill the cooling system with the correct coolant.

7C–11 CYLINDER HEAD 7C–11.1 Removal 1. Remove the air cleaner hose from the carburetor.

2. Disconnect the fuel line from the carburetor.

3. Remove coolant from cooling system.

4. Disconnect the spark plug wires, remove them from the fastener on the rocker cover.

5. Disconnect the water outlet hose at the intake manifold.

6. Remove the muffler/manifold.

–7C–18–

630, 631, 632 Loader Service Manual

7. Disconnect the throttle linkage, choke cable and the distributor vacuum advance hose from the carburetor.

8. Disconnect the throttle linkage at the governor.

9. Remove governor mounting bracket.

10. Remove the thermostat housing and remove the thermostat.

11. Remove the rocker cover and gasket.

12. Remove the rocker shaft bolts evenly and lift off the rocker shaft assembly.

13. Lift out the pushrods from their locations and keep them in their correct order.

14. Remove the cylinder head bolts and lift off the cylinder head and gasket. Do not lay the cylinder head flat on its face; damage to the spark plugs or gasket surface can result.

CYLINDER HEAD

7C–11.2 Installation 1. Clean all gasket material from the correct surfaces and put the cylinder head gasket on the cylinder block using pilot studs.

2. Install the cylinder head, remove pilot studs and install the cylinder head bolts. Tighten the bolts evenly (Fig. 7C–29) and in three steps to correct torque specifications.

3. Put oil on both sides of the pushrods and install them in respective bores.

4. Install the rocker arm shaft assembly on the cylinder head, put the pushrods on the adjustment screws. Tighten the bolts evenly to specifications.

N–02168

Fig. 7C–29

Torque Sequence

5. Make adjustment of the valve clearances.

6. Install the muffler/manifold.

7. Connect the distributor vacuum advance hose, the throttle linkage and choke cable to the carburetor.

8. Connect the water outlet hose to the intake manifold.

9. Install the thermostat in the cylinder head and install the gasket and thermostat housing.

10. Fill the cooling system with coolant.

11. Install governor and mounting bracket to the cylinder head and install the bolts.

12. Loosen governor adjustment bolts and install belt on governor sheave. Make adjustment of belt to specification and tighten bolts.

13. Connect the throttle linkage to the governor.

14. Connect the ignition wires to the spark plugs in the correct firing order.

15. Make second adjustment of the valve clearances to specification.

16. Install the rocker arm cover.

17. Install the air cleaner hose to the carburetor.

18. Make adjustment of the carburetor idle speed and mixture settings.

19. Make adjustment to governor.

–7C–19–

630, 631, 632 Loader Service Manual

7C–12 VALVE SPRING, RETAINER AND STEM SEAL (CYLINDER HEAD REMOVED) 7C–12.1 Removal 1. Remove the muffler/manifold and the spark plugs.

2. Compress the valve spring with a valve spring compressor. Remove the valve spring retainer locks, release the spring compressor and remove the spring and retainer.

3. Remove the seal and remove the valve.

7C–12.2 Installation 1. Install the valve and a new valve stem seal.

2. Install the valve spring and retainer over the valve stem.

3. Compress the valve spring. Put the retainer locks in the valve stem grooves and slowly release the spring compressor to engage the locks in the retainer tappets.

7C–13 VALVE SPRING, RETAINER AND STEM SEAL (CYLINDER HEAD INSTALLED) 7C–13.1 Removal 1. Disconnect the spark plug wires and remove them from the fastener on the rocker cover.

2. Remove the rocker cover and gasket.

3. Remove the rocker shaft bolts evenly and remove the rocker shaft assembly.

4. Remove the pushrods and keep them in correct order.

5. Remove the spark plugs.

6. Use an adapter to connect air pressure hose to cylinder to keep valve closed.

WARNING

Be sure piston is at top–dead–center or bottom–dead–center before applying air pressure. The engine can turn.

7. Compress the valve spring, and remove the valve spring retainer locks.

Release the spring compressor, remove the valve spring, retainer and the valve stem oil seal.

7C–13.2 Installation 1. Install a new seal over the valve stem.

2. Install the valve spring and retainer on the valve stem.

3. Compress the valve spring. Put the valve retainer locks in the valve stem grooves and slowly release the spring to engage the locks in the retainer.

Remove the air hose and adapter.

4. Put oil on both ends of the pushrods and install in respective bores. Install the rocker shaft assembly to the cylinder head, put the pushrods on the adjustment screws. Tighten the bolts evenly to specifications.

5. Make adjustment of valve clearances to specification.

6. Install the rocker cover.

–7C–20–

630, 631, 632 Loader Service Manual

7. Install the spark plugs and connect the wires to the spark plugs in the correct firing order.

8. Start the engine and run until engine reaches normal operating temperature.

9. Disconnect the wires from spark plugs and remove the rocker cover.

10. Make second adjustment of the valve clearances (hot) to specifications.

11. Install the rocker cover with a new gasket and tighten the fastening screws to specification.

12. Put the spark plug wires in the rocker cover fastener and connect them to respective spark plugs.

7C–14 WATER PUMP 7C–14.1 Removal 1. Remove coolant from the cooling system.

2. Loosen the governor adjustment bolts and remove drive belt.

3. Remove the sheave fastening bolts. Remove the sheave.

4. Loosen the clamps and remove the lower hose from the water pump.

5. Disconnect the manifold water hose from the water pump.

6. Remove the bolts which hold the water pump to cylinder block and remove the pump and gasket.

7C–14.2 Installation 1. Make sure that the contact surfaces of cylinder block and pump are clean.

2. If new pump is being installed, move water hose connection to new pump.

3. Put the pump and gasket on the cylinder block and fasten with bolts.

4. Connect the manifold water hose to the water pump and tighten clamp.

5. Connect lower hose on water pump and tighten the clamp.

6. Install the sheave and fan and fasten with bolts. Tighten the bolts to specification.

7. Install drive belt over crankshaft, fan and governor sheave and make adjustment of the belt tension to specifications. Tighten the governor fastening and adjusting bolt to specifications.

8. Make governor adjustment.

9. Fill radiator and install cap. Start the engine and check for leaks.

7C–15 ENGINE FRONT COVER, TIMING CHAIN AND CRANKSHAFT SPROCKETS 7C–15.1 Removal 1. Remove engine coolant by opening the drain valve on the radiator and removing the drain plug in the cylinder block.

2. Disconnect the radiator hoses from the engine.

3. Remove the governor belt and then remove the water pump sheave.

4. Remove the water pump.

–7C–21–

630, 631, 632 Loader Service Manual

5. Remove the crankshaft sheave, using a puller.

CRANKSHAFT SPROCKET

6. Remove the four bolts that hold the oil pan to the timing chain cover. Remove the six bolts that hold timing cover to cylinder block.

NOTE: Be careful not to cause damage to pan gasket. If gasket becomes damaged, it will be necessary to remove oil pan and make replacement of gasket. A damaged gasket will cause an oil leak.

7C–15.2 Remove Timing Cover 7. Remove the crankshaft oil thrower. Remove the camshaft sprocket retainer and bolts.

8. Remove the timing chain tightening arm. Remove the camshaft sprocket, and disconnect the timing chain.

9. Use puller to remove crankshaft sheave (Fig. 7C–30).

Tool–T64P–3590–F PI–02170

7C–15.3 Installation

Fig. 7C–30 Removing Crankshaft Sprocket

1. Install crankshaft sprocket if removed (Fig. 7C–31).

2. Install camshaft sprocket.

3. Install the timing chain over the camshaft and crankshaft sprockets so that the timing marks are in alignment (Fig. 7C–32).

4. Install camshaft sprocket retainer and bolts, then tighten bolts to specification. Bend locking tabs.

5. Install the tightening arm on the pivot pin while holding the tightening cam in the released position.

6. Install the oil thrower on the crankshaft. Install the timing chain tightener.

7. Install the timing cover gasket, oil pan gasket (if necessary) and the end seal on the front cover with an oil resistant sealer at the ends. Make alignment of the cover (Fig. 7C–33) with tool.

Tighten the fastening bolts evenly to specification and remove the alignment tool.

Tighten the oil pan bolts to specification.

8. Install the crankshaft sheave, making alignment of the slot with the crankshaft key. Tighten the fastening bolt to specifications.

CRANKSHAFT SPROCKET

Tool–T70P–6150

TIMING CHAIN

CRANKSHAFT GEAR TIMING MARK

PI–02171

Fig. 7C–31 Installing Crankshaft Sprocket

PI–02172

Fig. 7C–32

Timing Marks

9. Install the water pump and tighten the fastening bolts to specification.

10. Install the water pump sheave.

Install the governor belt and make adjustment of the tension of the belt to specifications.

11. Install the radiator hoses and tighten the clamps.

PI–02173

Fig. 7C–33 Aligning Oil Seal In Front Cover –7C–22–

630, 631, 632 Loader Service Manual

12. Fill the radiator with coolant.

REMOVING SEAL

13. Start engine and check for oil and water leaks.

7C–16 FRONT OIL SEAL 7C–16.1 Removal 1. Remove timing cover.

Handle

2. Push seal out from the inside of cover.

Tool–T–70P–6150

GASKET

7C–16.2 Installation 1. Push new seal into housing (Fig. 7C–34). Put a support under the housing near the seal to keep housing from breaking.

2. When installing the cover it is important that the oil seal is in alignment with the crankshaft and sheave boss.

7C–17 TIMING CHAIN TIGHTENER

Handle Attaching Bolt Cover Support N–02174

Fig. 7C–34

Installing Oil Seal In Front Cover

7C–17.1 Removal 1. Remove the timing chain cover (and oil pan if necessary).

2. Remove the timing chain tightener and arm by removing the two fastening bolts (Fig. 7C–35).

TIMING CHAIN TENSIONER TIMING CHAIN

7C–17.2 Installation 1. Install the tightener arm on the pivot pin.

2. Install the tightener and install the two bolts.

3. Install the timing chain cover (and oil pan if necessary).

7C–18 CAMSHAFT AND VALVE LIFTERS 7C–18.1 Removal 1. Remove the engine assembly and put the engine on a stand. Remove the crankcase oil.

TIMING CHAIN TENSIONER PAD

2. Disconnect the fuel line at the fuel pump.

N–02175

Fig. 7C–35 Tightener For Timing Chain

3. Loosen the governor adjustment bolts and remove the belt.

4. Remove the water pump sheave.

5. Remove the oil and fuel pumps from the cylinder block.

6. Disconnect the spark plug wires from the spark plugs and remove the rocker cover. Clean all gasket material from rocker arm cover and cylinder head.

7. Remove the distributor from the cylinder block.

8. Remove the rocker shaft bolts evenly and lift off the rocker shaft.

9. Remove the pushrods from the cylinder block and keep them in correct order.

10. Turn the complete engine over on the stand and remove the oil pan and gaskets.

11. Remove the crankshaft sheave, the timing cover and oil thrower.

12. Remove the timing chain tightener assembly.

–7C–23–

630, 631, 632 Loader Service Manual

13. Remove the camshaft sprocket and timing chain.

14. Remove the camshaft thrust plate and remove the camshaft (Fig. 7C–36).

15. Remove the tappets from the cylinder block and keep them in the correct order.

7C–18.2 Installation CAMSHAFT

1. Install a new timing cover oil seal (Fig. 7C–32).

Fig. 7C–36

N–02176

Removing Camshaft

2. Install the tappets.

3. Install the camshaft and install thrust plate in the camshaft groove. Tighten the fastening bolts to specification and bend the locking tabs.

4. Check the camshaft end play.

5. Put the timing chain on both sprockets. (Be sure marks on sprockets are in alignment). Install sprockets on crankshaft and camshaft, then tighten bolt to specification and bend the locking tabs.

6. Locate the tightener arm on the pivot pin and install the timing chain tightener.

7. Install the oil thrower on the crankshaft.

8. Put the gasket on the timing cover with an oil resistant sealer at the end.

Make alignment of the front cover and tighten the bolts evenly to specification.

9. Put a new gasket on the block flange using an oil resistant sealer compound at each end. Put the end seals (chamfered ends) into the groove, again using an oil resistant sealer at the ends and install the oil pan. Tighten the oil pan bolts to the correct torque. First tighten according to alphabetical order (A–B–C, etc.), then tighten according to numerical order (1–2–3, etc.).

10. Install the dipstick.

11. Install the crankshaft sheave, making alignment of the slot with the crankshaft key. Tighten the sheave fastening bolt to specification.

12. Turn the engine over on stand. Install the distributor and make timing adjustment.

13. Install a new gasket on the oil pump mounting flange and install the oil pump and filter assembly. Tighten the fastening bolts to specification.

14. Install a new gasket on the fuel pump flange and insert the pump lever through the slot in the block so that the lever is on the lobe of the camshaft.

Fasten the fuel pump to the cylinder block with two washers and bolts.

Tighten the bolts evenly to specifications.

15. Put oil on the contact surfaces of pushrods, valve stems and rocker arms.

Install the pushrods in respective bores and install the rocker shaft assembly.

Be sure to put ends of the pushrods on the adjustment screws. Tighten the rocker shaft fasting bolts evenly to specification.

16. Make adjustment of the valve clearances to specification.

17. Connect the distributor vacuum advance line to the carburetor.

–7C–24–

630, 631, 632 Loader Service Manual

18. Install the water pump sheave. Install the drive belt on the sheave and make adjustment of the belt tension to specifications. Connect the fuel line from the carburetor to the fuel pump.

19. Install distributor cap and connect wires to spark plugs.

20. Remove engine from stand.

21. Install the engine assembly in the Bobcat.

22. Start the engine and check for oil and water leaks.

23. Make second adjustment of the valves clearances (hot) to specification.

24. Install the rocker cover and a new gasket and fasten with screws and tighten to specifications.

25. Start engine, make adjustment of the ignition timing, if necessary.

26. Make adjustment of the carburetor idle speed and fuel–air mixture to specifications.

7C–19 FLYWHEEL RING GEAR 7C–19.1 Removal 1. Cut between teeth with a hacksaw.

2. Use a chisel to break the ring gear.

7C–19.2 Installation 1. Heat ring gear evenly to a temperature of not more than 600°F. (315°C.).

Temperatures more than 600° will cause damage to the hardness of the ring gear.

2. Install hot ring gear on flywheel.

7C–20 OIL PAN 7C–20.1 Removal 1. Remove the crankcase oil.

2. Remove the dipstick.

3. Remove the three bolts and remove the starter motor.

4. Remove the oil pan fastening bolts and remove the pan and gasket.

7C–20.2 Installation 1. Clean the oil pump inlet tube and screen assembly.

2. Clean the gasket surfaces of the block and oil pan. Be sure to clean the seal grooves in the timing chain cover and the rear seal retainer. The oil pan has a two–piece gasket. Put sealing compound on the block surface and the oil pan gasket surface. Install the oil pan and tighten the bolts evenly to specifications following first the alphabetical, then the numerical step shown in figure 7C–39.

3. Clean and install the starter motor and fasten it with the three bolts.

4. Fill the oil pan with the correct grade of engine oil and install the dipstick.

–7C–25–

630, 631, 632 Loader Service Manual

7C–21 OIL PUMP The oil pump and filter assembly is installed on the left side of the cylinder blocks and can be removed with the engine in the machine.

7C–21.1 Removal 1. Put a pan under the oil pump.

2. Remove the three bolts which hold the oil pump and filter assembly and remove the assembly (Fig. 7C–37).

3. Remove the oil filter from the oil pump.

CYLINDER BLOCK

7C–21.2 Installation 1. Install new oil filter on the oil pump assembly.

OIL PUMP ASSEMBLY

2. Make sure the contact surfaces are clean of old gasket material, then install the oil pump and filter assembly on the cylinder block, using a new gasket with sealing compound and fasten with the three bolts. Tighten the bolts to specifications.

N–02178

Fig. 7C–37 Removing Oil Pump

3. Check the oil level and add oil if necessary.

7C–22 CRANKSHAFT REAR OIL SEAL 7C–22.1 Removal 1. Remove the flywheel.

Handle

2. Remove the oil pan and gaskets.

3. Remove the rear oil seal carrier and remove the seal.

REAR OIL SEAL CARRIER

Tool–T70P–6165

7C–22.2 Installation 1. Install the new crankshaft rear oil seal (Fig. 7C–38).

2. Put a new gasket on the rear oil seal carrier, using a sealing compound at the ends, and the carrier on the block rear face. Tighten the bolts evenly to specifications.

GASKET INSTALLING SEAL IN CARRIER N–02179

3. Put new gaskets on the block flange using sealing compound at each end.

Install the end seals with the chamfered end into the grooves, again using a sealing compound and install the oil pan. Tighten the bolts to the correct torque and in steps (Fig. 7C–39).

Fig. 7C–38 Installing Oil Seal For Crankshaft

4. Install the flywheel on the crankshaft flange. Be sure contact surfaces of flywheel and crankshaft are clean. Tighten the bolts evenly to specifications.

7C–23 MAIN BEARINGS The cast iron crankshaft is supported by five bearings.

1

The main bearing caps must be kept in original positions. An arrow in the cap points to the front of the engine.

Location marks are on the caps.

The front cap has the letter “F”, second cap has the number “2”, the center cap has the letter “C”, the fourth cap has the number “4” and the rear cap does not have a mark.

2

3

4

5

6

7

18

L M A

N

O

P

Q

RC

17

B K J

I

H

G

F

ED

12

11

10

9

8

14

13

15

16

PI–02177

Fig. 7C–39

Tightening Sequence For Oil Pan Bolts

–7C–26–

630, 631, 632 Loader Service Manual

7C–23.1 Removal 1. Remove main bearing caps and thrustwashers. Keep the caps in order so each will be installed in original position.

2. Remove bearing halves from the cylinder block and from the caps.

3. Check caps and crankshaft for damage.

4. Install new bearing halves in the cylinder block, and in the bearing caps.

5. Make sure that the crankshaft and bearings are free from dirt and other foreign material.

6. Measure the bearing clearances using Plastigage (7C–5.9 “Main and Connecting Rod Bearings”).

7C–23.2 Installation 1. Clean the crankshaft and bearings.

2. Install the crankshaft thrustwashers.

3. Put oil on the bearing surfaces and install the bearing caps in their original positions and tighten the bolts to specification.

7C–24 CONNECTING ROD BEARINGS 7C–24.1 Removal 1. Turn the crankshaft for removal of number one connecting rod cap. Loosen the connecting rod bolts two or three turns and hit bolts to release the cap.

Completely remove the bolts and remove the cap. Keep caps in order so each will be installed in original position.

2. Remove the bearing halves from the connecting rods and from the caps.

7C–24.2 Installation 1. Install the upper and lower bearings in correct locations.

2. Measure the bearing clearances using Plastigage (7C–5.9 “Main and Connecting Rod Bearings”).

3. Install the connecting rod caps on the connecting rods in original positions and tighten the bolts to specifications.

7C–25 PISTONS AND CONNECTING RODS 7C–25.1 Removal 1. Remove the engine oil.

2. Remove coolant from the cooling system.

3. Disconnect the battery.

4. Disconnect the spark plug wires.

5. Disconnect the coolant hose at the intake manifold.

6. Remove the muffler/manifold.

7. Disconnect the throttle and choke linkages.

8. Disconnect the throttle linkage at the governor.

–7C–27–

630, 631, 632 Loader Service Manual

9. Remove the governor bracket bolts from cylinder head and remove governor.

10. Remove the thermostat housing and remove the thermostat.

11. Remove rocker cover and gasket.

12. Remove the rocker shaft bolts evenly and remove the rocker arm shaft assembly.

13. Remove the pushrods and keep them in correct order.

14. Remove the cylinder head bolts and remove the cylinder head and gasket.

Do not put the cylinder head flat on its face as damage to the spark plugs or gasket surface can result.

15. Remove the starter motor and oil pan.

16. Clean the oil pan and cylinder block faces and remove the end seals.

17. Loosen the bearing cap bolts several turns and hit bolts to release the cap.

Remove the bolts and remove the bearing cap. Keep caps in order so each can be installed in original positions. Push the piston and connecting rod out of the bore.

7C–25.2 Installation 1. Install the bearing halves in the connecting rods and end caps. Turn the crankshaft as necessary to fit each connecting rod to the crankshaft, but do not install the end cap.

2. Measure the bearing clearances using Plastigage (7C–5.9 “Main and Connecting Rod Bearings”).

3. Clean all bearing surfaces of Plastigage material. If necessary, use new bearings to give the correct clearance.

4. Install the connecting rods on the crankshaft and tighten the connecting rod bolts to specifications.

5. Install a new gasket on the block flange, using sealing compound at each end. Install the end seals, with the chamfered ends into the grooves, again using sealing compound.

6. Install the oil pan and tighten the bolts evenly to the correct torque following first the alphabetical, then the number order shown in figure 7C–39.

7. Clean and install the starter motor, fasten it with the two bolts.

8. Clean all gasket material from the contact surfaces and install the cylinder gasket on the cylinder block using alignment studs.

9. Install the cylinder head, remove alignment studs and install the cylinder head bolts. Tighten the bolts evenly in number order (Fig. 7C–29) and in three steps to specifications.

10. Put oil on both ends of the pushrods and install in respective bores.

11. Install the rocker shaft assembly on the cylinder head, put the pushrods on the adjustment screws. Tighten the bolts evenly to specifications.

12. Make adjustment of the valve clearances.

13. Install the muffler/manifold.

14. Connect the distributor vacuum advance line, the throttle and choke linkages to the carburetor.

–7C–28–

630, 631, 632 Loader Service Manual

15. Connect the coolant hose to the intake manifold.

16. Install the thermostat in the cylinder head and install the gasket and thermostat housing.

CRANKSHAFT OIL SLINGER

17. Fill the cooling system.

18. Connect the ignition wires to the spark plugs in the correct firing order.

19. Make adjustment of the valve clearances to specification.

N–02180

Fig. 7C–40

Oil Thrower On Crankshaft

20. Install the rocker cover.

21. Fill the oil pan with the correct grade of oil.

22. Connect the air cleaner hose to the carburetor.

23. Make adjustment of the carburetor idle speed and air/fuel mixture setting.

7C–26 CRANKSHAFT 7C–26.1 Removal 1. Remove the engine from Bobcat and put it in an engine stand.

2. Remove the flywheel from the crankshaft.

3. Loosen the governor fastening bolts and remove the drive belt.

4. Remove the sheave from the front of the crankshaft.

5. Remove the front cover.

6. Remove the oil thrower from the shaft (Fig. 7C–40). Remove the timing chain tightener and timing chain, then remove the crankshaft sprocket from the crankshaft.

7. Turn engine over, remove oil pan and oil inlet tube and screen.

8. Remove the four connecting rod bearing caps and keep them in order so that each will be installed on respective rods.

9. Remove the five main bearing caps and keep them in order so that each will be installed in their original position.

CRANKSHAFT THRUST WASHER

10. Carefully remove the crankshaft from the cylinder block.

7C–26.2 Installation 1. Install the main bearings in the cylinder block. Install the crankshaft and check the bearing clearances using the Plastigage method (7C–5.9 “Main and Connecting Rod Bearings”). Install respective main bearing caps and tighten to specification.

2. Check the crankshaft end play (Fig. 7C–17).

3. Install the correct thickness of thrustwashers to give the correct end play (Fig. 7C–41).

4. Check the connecting rod bearings using the Plastigage method (7C–5.9 “Main and Connecting Rod Bearings”).

–7C–29–

N–02181

Fig. 7C–41 Installing Thrust Washer 630, 631, 632 Loader Service Manual

5. Install rod bearings and the correct connecting rod caps in their original positions and tighten the cap bolts to specifications.

6. Install the oil inlet tube and screen.

7. Install the crankshaft sprocket and timing chain making sure that the timing marks are in alignment.

45°

8. Install the oil thrower, timing chain tightener and timing chain cover. Install the crankshaft sheave.

9. Install the oil pan and new gaskets. Tighten the oil pan fastening bolts to specification following first the alphabetical, then the numerical order shown in figure 7C–40.

10. Turn engine over again and install governor drive belt. Make belt adjustment to specified tension. Tighten adjustment bolts.

CAMSHAFT BEARING

11. Install the flywheel.

N–02182

Fig. 7C–42

12. Install the engine in Bobcat.

Camshaft Bearing Position

13. Fill the crankcase and the cooling system to the correct level with the specified oil and coolant. Start the engine and check for oil and water leaks.

7C–27 CAMSHAFT BEARINGS The service bearings for the camshaft are machined to fit and need no machining after installation. When one bearing needs replacement, it is best to install all three new, as camshaft alignment can be wrong if only one new bearing is installed.

Make sure that the oil holes in the bearings and cylinder block are in correct alignment before installation and that the splits in the bearings are upwards and outwards at 45 degrees to the vertical (Fig. 7C–42).

7C–27.1 Removal of Camshaft 1. Remove the flywheel.

2. Remove the crankshaft rear oil seal bracket.

3. Remove the camshaft bearings.

4. Check for dirt or other foreign material in the oil passages. Put sealing compound on the oil gallery plugs before installation.

7C–27.2 Installation 1. Install new camshaft bearings. Make sure that the oil holes in the bearings and cylinder block are in alignment. The splits in the bearings should be upwards and outwards at 45 degrees to the vertical (Fig. 7C–42).

2. Install a new crankshaft rear oil seal (Fig. 7C–39).

3. Put a new gasket on the rear oil seal bracket using sealing compound at the ends. Install the bracket on the cylinder block and tighten the bolts evenly to specification.

4. Install the flywheel on the crankshaft flange. Be sure contact surfaces are clean. Tighten the fastening bolts to specification.

5. Install the camshaft.

–7C–30–

630, 631, 632 Loader Service Manual

TECHNICAL DATA Paragraph Number ENGINE SPECIFICATIONS (630 WISCONSIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS (631 DEUTZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS (632 FORD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page Number

WISCONSIN (630)

DEUTZ (631)

8A–1 8B–1

FORD (632)

8C–1 8D–1 TECHNICAL DATA

TECHNICAL DATA

–8A––3–

630, 631, 632 Loader Service Manual

–8A––2–

630, 631, 632 Loader Service Manual

ENGINE SPECIFICATIONS, 630 (WISCONSIN) Paragraph Number ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . .

LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . .

8A–1

Page Number

WISCONSIN (630)

8A–1 8A–3

TECHNICAL DATA

–8A––1–

630, 631, 632 Loader Service Manual

–8A–0–

630, 631, 632 Loader Service Manual

630 LOADER SPECIFICATIONS 55.1 (1400)

138.6 (3521)

90°

69.9 (1775)

108.6 (2759)

30° 21.6 (550)

42.6 (1082)

86.3 (2192)

39.9 (1013)

75.6 (1919)

8.6 (217)

27° 7.1 (180) 95.3 (2419)

35.2 (894)

30.9 (786)

120.2 (3053)

58 (1473)

26° 35.3 (897,4) PI–02206

Where applicable, specifications conform to SAE standards and are subject to change without notice.

Dimensions are given for loader equipped with dirt bucket and standard tires and may vary with other bucket types. All dimensions are shown in inches.

Respective metric dimensions are given in millimeters enclosed by parentheses.

OPERATIONAL & PERFORMANCE Operating Weight . . . . . . . . 3900 lbs. (1760 kg) Rated Operating Capacity . . 1000 lbs. (454 kg) Lift Capacity to Maximum Height . . . . . . . . 1200 lbs. (544 kg) Tipping Load . . . . . . . . . . . . . 2050 lbs. (930 kg) Hydraulic Function Time: Move Lift Arms to Maximum Height . . . . . . . . . . . . . 4 seconds Lower Lift Arms from Maximum Height . . . . . . . . . . . . 2.5 seconds Move Bucket to Dumping Position . . . . . . . . . . . 2.2 seconds Move Bucket to Retracted Position . . . . . . . . . . 1.6 seconds Travel Speed . . . . . 0 to 6.6 MPH (10,62 km/hr.)

Controls: Vehicle . . . . . Direction & speed controlled by two hand operated levers.

Loader Functions . . . . . . Lift and tilt functions controlled by separate foot pedals. Auxiliary function controlled by right steering lever.

Engine . . Hand lever throttle, manual choke & key–type starter switch.

Main Drive . . . . . . . . . . . . . . . . . . . Hydrostatic Brakes . . . . . . . Mechanical disc., foot or hand operated pedal.

45.6 (1152) 53.5 (1359)

Maximum Governed RPM (Full Load) . . . . . . . . . . . . . . . . . . . . 2500 RPM Torque . . . . . . . 66 ft.–lbs. (89 Nm) @ 1800 RPM Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . 4 Bore/Stroke . . . . . . . . . . . 3.25/3.25(82,55/82,55) Displacement . . . . . . . . . . . 107.7 cu. in. (1,76 L) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . Air Lubrication . . . . . . . . . . Pressure system W/filter Crankcase Ventilation . . . . . . . . . . Vented fill cap Air Cleaner . . . . Dry replaceable paper element

ELECTRICAL

LOADER HYDRAULICS

Transmission . . . . Hydrostatic, infinitely variable, fully reversing (2).

Final Drive . . . . . . . . . . #60 roller chain in sealed chaincase with oil lubrication.

Alternator . . . . . . . . . . . . Flywheel type 25 amps.

Battery . . . . . . . . . . . . . 12 volt, 410 cold cranking amps. @ 0°F (–17,8°C) 100 min. reserve capacity Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt

DRIVE SYSTEM

Pump . . . . . . . . . . . . . . . Engine driven vane type Pump Capacity . . . . . . . . 9.5 GPM (36 L/min.) @ 2500 RPM System Relief Setting . . . . 1950 PSI (12065 kPa) CAPACITIES Hydraulic Fluid Filter . . . . . . . . . 40 micron bronze filter in port block from suction, Fuel . . . . . . . . . . . . . . . . . . . . . . . 10 gal. (37,85 L) replaceable element, 10 micron in Engine Lubricant Including Filter . . . 1 gal. (3,3 L) return line from cooler. Hydrauic System . . . . . . . . . . . . . 6 gal. (22,71 L) Cylinder . . . . . . . . . . . . . . . . . . . . . . Doubleacting (Includes 3.5 gallons [13,26 L] reservoir) Chaincase Reservoir . . . . . . . . . 5 gal. (18,925 L)

Bore Dia. Rod Dia. Stroke

.Lift Cyl. (2) 2.00 (50,80) 1.25 (31,75) 25.00 (635)

Tilt Cyl. (1) 3.25 (82,55) 1.50 (38,1) 12.30 (312,42)

TIRES Standard . . . . . . . . 7:00 x 15,6 Ply Rating Nylon W/Bar Lug Tread

ENGINE (Engine Manufacturer’s Rating) Make . . . . . . . . . . . . . . . . . . . . . . . . . Wisconsin Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VH4D Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline Horsepower . . . . . . . . . . . . . . . . . 28 HP (21 Kw)

Revised Mar. 85

Control Valves . . . . . . . 3 spool, open center type W/float–detent on lift, detent on auxiliary Fluid Lines . . . . . . . SAE standard full flow tubes, hoses & fittings.

–8A–1–

MACHINE WEIGHT

(W/out Attachments)

Shipping . . . . . . . . . . . . . . . 3400 lbs. (1532,3 kg)

630, 631, 632 Loader Service Manual

8A TECHNICAL DATA 8A–1 ENGINE SPECIFICATIONS, 630 (Wisconsin) All specifications are given in inches with metric in parenthesis 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2550 Idle RPM (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000–1200 Idle RPM (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2640 Engine Oil Pressure (Engine Warm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5 PSI (27,6–34,5 kPa) 8A–1.1 Fuel Specifications Always use clean fuel. Do not let the tank become empty.

Type of Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regular gasoline, 85–90 octane.

8A–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.

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

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

+70

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

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

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) Revised Mar. 85

–8A–2–

630, 631, 632 Loader Service Manual

8A–1.4 Crankshaft Crank Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.876–1.875 (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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .003–.004 (0,0762–0,1020)

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 Bushing to Piston Pin Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0005–.0011 (0,013–0,028)

8A–1.7 Piston, Piston Pin, Piston Rings Piston to Cylinder at Piston Skirt (Wide Skirt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Pin to Piston Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Ring Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Ring Side Clearance in Grooves: Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2nd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3rd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.0035–.0040 (0,089–0,102) .0000–.0008 (0,000–0,020) .010–.020 (0,254–0,508) .002–.0035 (0,051–0,089) .001–.0025 (0,025–0,064) .001–.0025 (0,025–0,064) .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 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.

8A–1.10 Starter The starter is the gear drive type and is 12 volt, negative ground.

8A–1.11 Engine Torque Specifications Item Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manifold Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pan Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rod Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Bearing Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

–8A–3–

Ft. Lbs. Nm 22–24 . . . . . . . . . . . . . . . . 30–33 25–30 . . . . . . . . . . . . . . . . 34–41 18–23 . . . . . . . . . . . . . . . . 24–31 14–18 . . . . . . . . . . . . . . . . 19–24 6–9 . . . . . . . . . . . . . . . . . . . 8–12 22–28 . . . . . . . . . . . . . . . . 30–38 40–50 . . . . . . . . . . . . . . . . 54–68 25–30 . . . . . . . . . . . . . . . . 34–41 40–60 . . . . . . . . . . . . . . . . 54–81

630, 631, 632 Loader Service Manual

–8A–4–

630, 631, 632 Loader Service Manual

ENGINE SPECIFICATIONS, 631 (DEUTZ) Paragraph Number

Page Number DEUTZ (631)

ENGINE SPECIFICATIONS (F2L411D) . . . . . . . . . . . . . .

LOADER SPECIFICATIONS (F2L411D) . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS (F2L511) . . . . . . . . . . . . . . . .

LOADER SPECIFICATIONS (F2L511 . . . . . . . . . . . . . . . .

–8B––1–

8B–1 8B–2

8B–1 8B–4 8B–5 8B–8

630, 631, 632 Loader Service Manual

–8B–0–

630, 631, 632 Loader Service Manual

631 LOADER SPECIFICATIONS 55.1 (1400)

138.6 (3521)

90°

69.9 (1775)

108.6 (2759)

37° 21.6 (550)

42.6 (1082)

86.3 (2192)

39.9 (1013)

75.6 (1919)

8.6 (217)

27° 7.1 (180) 95.3 (2419)

35.2 (894)

30.9 (786)

58 (1473)

26° 35.3 (897,4)

120.2 (3053)

PI–02206

Dimensions are given for loader equipped with dirt bucket and standard tires and may vary with other bucket types. All dimensions are shown in inches.

Respective metric dimensions are given in millimeters enclosed by parentheses.

OPERATIONAL & PERFORMANCE Operating Weight . . . . . . . . 3900 lbs. (1760 kg) Rated Operating Capacity . . 1000 lbs. (454 kg) Lift Capacity to Maximum Height . . . . . . . . 1200 lbs. (540 kg) Tipping Load . . . . . . . . . . . . . 2100 lbs. (950 kg) Hydraulic Function Time: Move Lift Arms to Maximum Height . . . . . . . . . . . . 3.8 seconds Lower Lift Arms from Maximum Height . . . . . . . . . . . . 3.0 seconds Move Bucket to Dumping Position . . . . . . . . . . . 2.8 seconds Move Bucket to Retracted Position . . . . . . . . . . 2.4 seconds Travel Speed . . . . 0 to 6.6 MPH (0–10,6 km/hr.)

Controls: Vehicle . . . . . Direction & speed controlled by two hand operated levers.

Loader Functions . . . . . . Lift and tilt functions controlled by separate foot pedals. Auxiliary function controlled by right steering lever.

Engine . . . . Hand lever throttle, and key–type starter switch.

Main Drive . . . . . . . . . . . . . . . . . . . Hydrostatic Brakes . . . . . . . Mechanical disc., foot or hand operated pedal.

ENGINE (Engine Manufacturer’s Rating) Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deutz Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2L511 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . #2 Diesel Horsepower . . . . . . . . . . . . . . . 28.5 HP (21 Kw)

Revised Mar. 85

45.6 (1152) 53.5 (1359)

Where applicable, specifications conform to SAE standards and are subject to change without notice.

Maximum Governed RPM (Full Load) . . . . . . . . . . . . . . . . . . . . 2500 RPM Torque . . . . . 64.9 ft.–lbs. (88 Nm) @ 2000 RPM Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . 2 Bore/Stroke . . . . . . . . . . 3.973/4.14(100/105,16) Displacement . . . . . . . . . . . . 101 in.# (1655 cm#) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . Air Lubrication . . . . . . . . . . . . . Pressure–gear pump Crankcase Ventilation . . . . . . . . Open breathing Air Cleaner . . . . Dry replaceable paper element

ELECTRICAL

LOADER HYDRAULICS

Transmission . . . . Hydrostatic, infinitely variable, fully reversing (2).

Final Drive . . . . . . . . . . #80 roller chain in sealed chaincase with oil lubrication; W/gear and chain reduction.

Alternator . . . . . . . . . . . . . . Belt driven, 42 amps.

Battery . . . . . . . . . . . . . 12 volt, 410 cold cranking amps. @ 0°F (–17,8°C) 100 min. reserve capacity Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt

DRIVE SYSTEM

Pump . . . . . . . . . . . . . . Engine driven vane pump Pump Capacity . . . . . . . . 9.5 GPM (36 L/min.) @ 2500 RPM System Relief Setting . . . . . 1950 PSI (12,1 kPa) Hydraulic Fluid Filter . . . . . . . . . 40 micron bronze CAPACITIES filter in port block from suction, replaceable element, 10 micron in Fuel . . . . . . . . . . . . . . . . . . . . . . . . . 10 gal. (38 L) return line from cooler. Engine Lubricant Including Filter . . . 1 gal. (3,8 L) Cylinder . . . . . . . . . . . . . . . . . . . . . . Doubleacting Hydraulic System . . . . . . . . . . . . . . . 6 gal. (23 L) (Includes 3.5 gallons [13,26 L] reservoir) Chaincase Reservoir . . . . . . . . . . . . 5 gal. (19 L) .Lift Cyl. (2) Tilt Cyl. (1) Bore Dia. 2.00 (50,80) 3.25 (82,55) Rod Dia. 1.25 (31,75) 1.50 (38,10) TIRES Stroke 25.00 (635,0) 12.30 (312,42) Standard . . . . . . . . 7:00 x 15,6 Ply Rating Nylon W/Bar Lug Tread Control Valves . . . . . . . 3 spool, open center type WEIGHT (Without W/float–detent on lift, detent MACHINE on auxiliary Attachments) Fluid Lines . . . . . . . SAE standard full flow tubes, hoses & fittings. Shipping . . . . . . . . . . . . . . . . . 4240 lbs. (1914 kg)

(Deutz F2L411D) –8B–1–

630, 631, 632 Loader Service Manual

8B–1 ENGINE SPECIFICATIONS, 631 (Deutz) All specifications are given in inches with metric in parenthesis Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.2 cu. in. (1,39 L) Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.62 (91,95 L) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 (104,90) Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1 Oil Capacity W/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 gal. (3,79 liters)

8B–1.1 Fuel System Pressure of Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 5 PSI (27,6–34,5 kPa) Make of Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch PFR2K70A414/2 Make of Fuel Injection Nuzzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DLLA 152 S 533 Release Pressure of Injection Nozzle New: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2560–2673 PSI (17651–18480 kPa) Used: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2488–2602 PSI (17154–17940 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 Governor, Front Cover and Throttle Distance from Governor Bearing Cup to Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37–3.38 (85,6–85,85) End Play in Throttle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .008–.043 (0,2–1,09 mm) Engine High Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2625–2675 RPM Engine Low Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050–1150 RPM

8B–1.3 Cylinder Head and Valves I.D. of Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315–.3155 (8,00–8,013 mm) I.D. of Bore for Exhaust Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,5354–1,5364 (38,99–39,025) I.D. of Bore for Intake Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.378–1.379 (35,00–35,026) Valve Seat Width, Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .040–.055 (1,01–1,4) Valve Seat Width, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .031–.033 (0,78–0,84) Valve Seat Angle, Exhaust and Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .083–.095 (2,11–2,41 mm) Valve Clearance, Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 (0,15 mm) Minimum Free Length of Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.81 (45,97 mm) Maximum Length of Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.114 (231,5)

8B–1.4 Cylinder, Piston and Connecting Rod Cylinder Bore (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.622–3.623 (91,99–92,024) Maximum Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .012 (0,304 mm) Piston Diameter (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6197–3.620 (91,940–91,948) Piston Diameter (1st Oversize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6394–3.6397 (92,440–92,448) Piston Diameter (2nd Oversize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.659–3.6594 (92,938–92,949) Wrist Pin Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1812–1.1814 (30,002–30,007) Wrist Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1809–1.1811 (29,995–29,99) Piston Ring Side Clearance, Top Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .003–.004 (0,008–0,112) Piston Ring Side Clearance, 2nd & 3rd Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .003–.0048 (0,09–0,122) Piston Ring Side Clearance, Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 (0,15) Ring End Gap, Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .014–.022 (0,355–0,558 mm) Maximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .079 (2,0 mm) Distance Between Piston & Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .031–.039 (0,78–0,99) Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355–575 PSI (2447,7–3964,6 kPa) NOTE: The cylinders must be within 35 PSI (241,3 kPa) of each other.

Revised Mar. 85

(Deutz F2L411D) –8B–2–

630, 631, 632 Loader Service Manual

I.D. of Hole in Connecting Rod for Wrist Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3386–1.3392 (34,00–34,016) I.D. of Wrist Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1827–1.1841 (30,04–30,076) I.D. of Hole in Connecting Rod for Crankshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2441–2.2448 (57,00–57,017) 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–1.5 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0067–2.0075 (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 8B–1.6 Lubrication System Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.5 psi (196,5 kPa) at 1500 RPM End Clearance in Oil Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .004 (,1 mm) 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 API service classification 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

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

+70

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

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

Revised Mar. 85

(Deutz F2L411D) –8B–3–

630, 631, 632 Loader Service Manual

8B–1.7 Torque Specifications (Deutz Engine) ITEM

PRELOADING

TIGHTENING*

TOTAL

Cylinder Head Bolts

21.5 ft.–lbs. (29 Nm)

30° 60° 60°

150°

Cylinder Head Brass Plug

59 ft.–lbs. (80 Nm)

–––

59 ft.–lbs. (80 Nm)

Injector Hold–Down

21.5 ft.–lbs. (29 Nm)

60° 60° –

120°

Connecting Rod

21.5 ft.–lbs. (29 Nm)

30° 60° –

90°

–

–––

25 ft.–lbs. (34 Nm)

Bearing Support

21.5 ft.–lbs. (29 Nm)

30° 60° –

60°

Blower Mounting Bolts

–

–––

25 ft.–lbs. (34 Nm)

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°

Camshaft Bearing Flange

V–Belt Pulley

* One flat on hex head equals 60°.

8B–1.8 Special Tools (Deutz) 100020 100030 101900 101910 110030 121100 122100 122230 122800 122970 123310 123830 124020 130300 130510 131000 139000 141000 143620 150010 150800

Revised Mar. 88

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 (Deutz F2L411D) –8B–4–

630, 631, 632 Loader Service Manual

8B–2 ENGINE SPECIFICATIONS, 631 (Deutz) All specifications are given in inches with metric in parenthesis Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100.7 cu.in. (1650 cm#) Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.94 (100 mm) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.133 (105 mm) Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1 Oil Capacity W/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 gals. (4,5 L)

8B–2.1 Fuel System Pressure of Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5 PSI (0,28 bar–0.35 bar) Make of Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch DILLA 149 S 774 Make of Fuel Injection Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch Release Pressure of Injection Nozzle (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2646–2764 (180–188 bar) (Used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2572–2690 (175–183 bar) Distance from Injection Pump Mounting Flange to Camshaft Base Circle (Including Gasket and Shims) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2519–3.2559 (82,6–82,7 mm) Injection Timing (Start of Injection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25° BTDC Capillary Tube

8B–2.2 Governor, Front Cover and Throttle Distance from Governor Bearing Cup to Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.334–3.374 (84,7–85,7 mm) End Play in Throttle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .008–.043 (0,2–1,1 mm) Engine High Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2625–2675 RPM Engine Low Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050–1150 RPM

8B–2.3 Cylinder Head and Valves I.D. of Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3149–.3155 (8,0–8,015 mm) I.D. of Bore for Exhaust Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.575–1.577 (40,0–40,025 mm) I.D. of Bore for Intake Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.791–1.792 (45,5–45,525 mm) Valve Seat Width, Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .059–.0826 (1,5–2,1 mm) Valve Seat Width, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .059–.0826 (1,5–2,1 mm) Valve Seat Angle, Exhaust and Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Valve Stem Diameter, Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3127–.3133 (7,945–7,96 mm) Valve Stem Diameter, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311–.312 (7,92–7,94 mm) Maximum Distance Valves may be Recessed into Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232 (5,9 mm) Maximum Distance Valves may Protrude from Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 (5,2 mm) Valve Clearance, Cold (Intake & Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 (0,15 mm) Minimum Free Length of Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 (59 mm) Length of Head Bolts (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.381–7.421 (187,5–188,5 mm) Max. Length of Head Bolts (Used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.460 (189,5 mm)

8B–2.4 Cylinder, Piston and Connecting Rod Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420–449 PSI (2895.9–3095.8 kPa) Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.937–3.9763 (100,000–100,022 mm) Maximum Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .004 (0,1 mm) Piston Diameter (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9354–3.9361 (99,951–99,968 mm) Piston Diameter (1st Oversize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9551–3.9554 (100,451–100,468 mm) Piston Diameter (2nd Oversize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.975–3.9782 (100,951–100,968 mm) Wrist Pin Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38965–1.38999 (35,004–35,010 mm) Wrist Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38927–1.38950 (34,994–35,000 mm) Piston Ring Side Clearance, Top Compression Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .004–.006 (0,105–0,145 mm)

Revised Mar. 85

(Deutz F2L511) –8B–5–

630, 631, 632 Loader Service Manual

Piston Ring Side Clearance Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .002–.003 (0,040–0,072 mm) Compression Ring End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0138–.0216 (0,35–0,55 mm) Slotted Oil Control Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0098–.0157 (0,25–0,40 mm) Maximum Ring End Gap (All) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .030 (0,8 mm) Piston Crown Clearance (Measure with Lead Wire) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .039–.047 (1,0–1,2 mm) I.D. of Hole in Connecting Rod For Wrist Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4961–1.5 (38,000–38,020 mm) I.D. of Wrist Pin Bushing (Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.381–1.3795 (35,036–35,080 mm) I.D. of Hole in Connecting Rod For Connecting Rod Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24–2.25 (57,0–57,025 mm) Connecting Rod Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .002–.0043 (0,05–0,108 mm) Connecting Rod Bearing Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 (0,15) Connecting Rod Bearing Side Clearance (End Play) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .007–.011 (,170–,271) Connecting Rod Bearing Side Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0236 (0,6 mm)

8B–2.5 Camshaft, Crankshaft, Bearings Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010–.024 (0,25–0,6 mm) I.D. of Camshaft Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8902–1.8922 (48,01–48,064 mm) Diameter of Crankpin (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0460–2.0468 (51,971–51,990 mm) Diameter of Crankpin (1st Undersize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0263–2.0271 (51,471–51,490 mm) Diameter of Crankpin (2nd Undersize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0066–2.0074 (50,971–50,990 mm) Diameter of Crankpin (3rd Undersize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9868–1.9876 (50,471–50,490 mm) Width of Crankpin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.338–1.34 (34,000–34,062 mm) Diameter of Crankshaft Main Journals (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5185–2.5193 (63,971–63,990 mm) Diameter of Crankshaft Main Journals (1st Undersize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.479–2.487 (63,471–63,490 mm) Diameter of Crankshaft Main Journals (2nd Undersize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.479–2.480 (62,971–62,990 mm) Diameter of Crankshaft Main Journals (3rd Undersize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4595–2.4602 (62,471–62,490 mm) Crankshaft Center Journal (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.361–2.3618 (59,971–59,990 mm) Crankshaft Center Journal (1st Undersize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3414–2.3421 (59,471–59,490 mm) Crankshaft Center Journal (2nd Undersize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3217–2.3224 (58,971–58,990 mm) Crankshaft Center Journal (3rd Undersize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3020–2.3028 (58,471–58,490 mm) Maximum Out–of–Round Tolerance of Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00275 (0,01 mm) End Play of Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0078–.0157 (0,2–0,4 mm) Hardness of Journals (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 HRC Hardness of Journals (Normal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55–61 HRC

8B–2.6 Lubrication System Oil Pressure Minimum at Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25 PSI (49,98 kPa) End Clearance in Oil Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .004 (0,1 mm) 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 between the “add” and “full” mark on the dipstick. Use a good quality detergent motor oil that meets the API Service Classification CD. Use of proper SAE viscosity for expected temperature conditions.

Revised Mar. 88

(Deutz F2L511) –8B–6–

630, 631, 632 Loader Service Manual

8B–2.7 Torque Specifications ITEM

PRELOADING

TIGHTENING*

TOTAL

Cylinder Head Bolts

22 ft.–lbs. (30 Nm)

45° 45° 30°

165°

Injector Hold–Down

22 ft.–lbs. (30 Nm)

–––

–

Connecting Rod

22 ft.–lbs. (30 Nm)

30° 30° 30°

90°

Main Bearing Support Bracket Bolt (1 Only)

22 ft.–lbs. (30 Nm)

60° – –

60°

Main Bearing Bolts

22 ft.–lbs. (30 Nm)

30° 30° –

60°

Blower Mounting Bolts

22 ft.–lbs. (30 Nm)

60° – –

60°

V–Belt Pulley

22 ft.–lbs. (30 Nm)

90° – –

90°

Intake Manifold

11 ft.–lbs. (15 Nm)

–––

–

Crankshaft Gear

22 ft.–lbs. (30 Nm)

30° 30° –

60°

Oil Suction Pipe

37 ft.–lbs. (50 Nm)

–––

120°

Flywheel

22 ft.–lbs. (30 Nm)

60° 60° –

120°

Rocker Arm Bolts

20 ft.–lbs. (28 Nm)

–––

–

Counter Balance Weights

22 ft.–lbs. (30 Nm)

30° 30° –

60°

Anti–Fatigue Bolt

26 ft.–lbs. (35 Nm)

–––

–

* One flat on hex head equals 60°.

8B–2.8 Special Tools (F2L511 Deutz) 003–1085 003–0463 003–0536 003–0464 003–1091 003–1076 003–0426 003–3409 003–0500 003–0501 003–0430

Revised Mar. 85

Capillary tube Extractor tool Slide hammer Adapter Spacer Compression Tester Removing scratches on cylinder head Valve seat removal tool (Kit) Degree scale to tighten heads To install spring on push rod tube Ring compressor

(Deutz F2L511) –8B–7–

630, 631, 632 Loader Service Manual

–8B–8–

630, 631, 632 Loader Service Manual

ENGINE SPECIFICATIONS, 632 (FORD) Paragraph Number ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . .

LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . .

8C–1

Page Number 8C–1 8C–6 FORD (632)

–8C––1–

630, 631, 632 Loader Service Manual

–8C–0–

630, 631, 632 Loader Service Manual

632 LOADER SPECIFICATIONS 55.1 (1400)

135.6 (344.2)

100°

69.7 (1770)

109.6 (2768.6)

30°

21.9 (556.3) 86.3 (2192)

44.2 (1122.7)

35.8 (909.3)

75.6 (1919)

8.1 (205.7)

27° 7.5 (190.5) 95.2 (2418)

35.2 (894)

30.9 (786)

120.2 (3053)

58.3 (1480.8)

26° 32.3 (820.4) PI–02206

Where applicable, specifications conform to SAE standards and are subject to change without notice.

Dimensions are given for loader equipped with dirt bucket and standard tires and may vary with other bucket types. All dimensions are shown in inches.

Respective metric dimensions are given in millimeters enclosed by parentheses.

OPERATIONAL & PERFORMANCE Operating Weight . . . . . . . . 3925 lbs. (1781 kg) Rated Operating Capacity . . 1000 lbs. (454 kg) Lift Capacity to Maximum Height . . . . . . . . 1200 lbs. (540 kg) Tipping Load . . . . . . . . . . . . . 2100 lbs. (950 kg) Hydraulic Function Time: Move Lift Arms to Maximum Height . . . . . . . . . . . . . 4 seconds Lower Lift Arms from Maximum Height . . . . . . . . . . . . 2.5 seconds Move Bucket to Dumping Position . . . . . . . . . . . 2.2 seconds Move Bucket to Retracted Position . . . . . . . . . . 1.6 seconds Travel Speed . . . 0 to 6.6 MPH (0–10,52 km/hr.)

Controls: Vehicle . . . . . Direction & speed controlled by two hand operated levers.

Loader Functions . . . . . . Lift and tilt functions controlled by separate foot pedals. Auxiliary function controlled by right steering lever.

Engine . . Hand lever throttle, manual choke & key–type starter switch.

Main Drive . . . . . . . . . . . . . . . . . . . Hydrostatic Brakes . . . . . . . Mechanical disc., foot or hand operated pedal.

Maximum Governed RPM ELECTRICAL (Full Load) . . . . . . . . . . . . . . . . . . . . 2500 RPM Torque . . . . . . . 71 ft.–lbs. (96 Nm) @ 1800 RPM Alternator . . . . . . . . . . . . . . Belt driven, 37 amps.

Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . 4 Battery . . . . . . . . . . . . . 12 volt, 410 cold cranking Bore/Stroke . . . . . . 3.183/3.056(80,975/77,622) amps. @ 0°F (–18°C) 100 min. reserve Displacement . . . . . . . . . . . . . . . 98 cu. in. (1,6 L) capacity Cooling System . . . . . . . . . . . . . . . . . . . . . . Liquid Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt Crankcase Ventilation . . . . . . . . . . Filter rod vent Air Cleaner . . . . Dry replaceable paper element

DRIVE SYSTEM LOADER HYDRAULICS Pump . . . . . . . . . . . . . . . Engine driven vane type Pump Capacity . . . . . . . . 9.5 GPM (36 L/min.) @ 2500 RPM System Relief Setting 1950 PSI (123,04 kg. cm#) Hydraulic Fluid Filter . . . . . . . . . 40 micron bronze filter in port block from suction, replaceable element, 10 micron in return line from cooler.

Cylinder . . . . . . . . . . . . . . . . . . . . . . Doubleacting

Bore Dia. Rod Dia. Stroke

.Lift Cyl. (2) 2.00 (50,80) 1.25 (31,75) 25.00 (635)

Tilt Cyl. (1) 3.25 (82,55) 1.50 (38,1) 12.30 (312,42)

Revised Mar. 85

Transmission . . . . Hydrostatic, infinitely variable, fully reversing (2).

Final Drive . . . . . . . . . . #60 roller chain in sealed chaincase with oil lubrication;

CAPACITIES Cooling System . . . . . . . . . . . . . . . . 10 qts. (9,5 L) Fuel . . . . . . . . . . . . . . . . . . . . . . . 10 gal. (37,85 L) Engine Lubricant Including Filter . . . 1 gal. (3,8 L) Hydraulic System . . . . . . . . . . . . . 6 gal. (22,71 L) (Includes 3.5 gallons [13,26 L] reservoir) Chaincase Reservoir . . . . . . . . . 5 gal. (18,925 L)

TIRES Standard . . . . . . . . 7:00 x 15,6 Ply Rating Nylon W/Bar Lug Tread

ENGINE (Engine Manufacturer’s Rating) Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ford Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–98 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline Horsepower . . . . . . . . . . . . . . . . . 30 HP (22 Kw)

45.6 (1152) 53.4 (1356.3)

Control Valves . . . . . . . 3 spool, open center type W/float–detent on lift, detent on auxiliary Fluid Lines . . . . . . . SAE standard full flow tubes, hoses & fittings.

–8C–1–

MACHINE WEIGHT

(W/out Attachments)

Shipping . . . . . . . . . . . . . . . 3400 lbs. (1532,3 kg)

630, 631, 632 Loader Service Manual

8C–1 ENGINE SPECIFICATIONS, 632 (FORD) All specifications are given in inches with metric in parenthesis.

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 CID (1600 cc) Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.188 (80,98) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.056 (77,62) Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2 – 4 – 3 Oil Capacity W/Filter (Approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 qts. (3,311 L)

8C–1.1 Fuel Specifications Always use clean fuel. Do not let the tank become empty.

Type of Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regular gasoline, 85–90 octane

Fuel System Float Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5/32” (29,37 mm) Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5–5.0 PSI (4,75–6,78 kPa)

8C–1.2 Engine Oil Check oil level after 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

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

+70

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

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

Revised Mar. 85

–8C–2–

630, 631, 632 Loader Service Manual

Lubrication System Oil Pressure–Hot @ 2000 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–40 PSI (241,3–275,8 kPa) Oil Pump–Rotor Assembly End Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .001–.004 (0,025–0,102) Outer Race to Housing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005–.0075 (0,13–0,195) Clearance Between Inner & Outer Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 (0,160) 8C–1.3 Cylinder Heads Gasket Surfaces Flatness per 12” (304,8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005 (0,0375) Valve Guide Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3113–.3125 (7,907–7,938) Valve Guide Replacement Bushing Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4383–.4391 (11,113–11,153) Valve Seat Width–Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0625 (1,59) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0781 (1,98) Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° Valve Seat Insert Exhaust Inside Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2680–1.2685 (32,207–32,330) Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215–.2225 (5,524–5,652) 8C–1.4 Valve Mechanism Lash Intake–(Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .008–.010 (0,20–0,25) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .018–.020 (0,45–0,51) Stem Diameter–Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3098–.3105 (7,868–7,886) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3098–.3096 (7,846–7,863) Oversize .003 (0,076) Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3128–.3155 (7,944–7,962) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3119–.3126 (7,922–7,939) Oversize .015 (0,38) Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3248–.3255 (8,248–8,266) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3239–.3246 (8,226–8,243) Stem to Guide Clearance Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0008–.0027 (0,020–0,068) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0017–.0036 (0,043–0,091) Length–All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.345–4.365 (110,4–110,9) Head Diameter Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.559–1.550 (39,60–39,40) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.340–1.330 (34,00–33,80) Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44–1/2°–45° Face Runout–Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .002 (0,05) Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.48 (37,6) Spring Assembled Height Pad to Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.263 (32,08) Spring Load at Assembled Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44–49 lbs. (19,96–22,23 kg) Push Rod Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250–.254 (6,35–6,45) Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.59–7.62 (192,79–193,55) Max. Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .012 (0,300) Tappet–Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.85 (47,0) Stem Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5120–.5122 (13,004–13,009) Block Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .516–.517 (13,106–13,107) Clearance to Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0005–.002 (0,013–0,05) Rocker Shaft–Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .623–.624 (15,83–15,85) Rocker Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .625–.6265 (15,88–15,913) Shaft Clearance in Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .001–.0035 (0,03–0,089) Rocker Arm Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54:1 8C–1.5 Camshaft Journal Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5596–1.5605 (39,617–39,637) Bearing–I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5615–1.5620 (39,662–39,675) Length Front & Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 (57,4) Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 (57,4) Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .001–.0023 (0,025–0,058) Wear Limit .003 (0,076) Bore For Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6885–1.6895 (42,888–42,913) Oversize Bearing OD or OD Standard IS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .020 (0,513) End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0024–.075 (0,061–0,192) Thrust Plate Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1755–.1775 (4,458–4,509) Valve Timing– Inlet Opens–°BTDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–21 Inlet Closes–°ABDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51–55 Exhaust Opens–°BBDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51–60 Exhaust Closes–°ATDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17–22 Inlet Cam Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2108 (5,3548) – 0.2356 (5,9851) Exhaust Cam Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2176 (5,5276) – 0.2321 (5,8943)

Revised Mar. 85

–8C–3–

630, 631, 632 Loader Service Manual

8C–1.6 Crankshaft Main Bearing Journal Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1253–2.1261 (53,983–54,003) Main Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0005–.002 (0,013–0,051) Rod Bearing Journal Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.968–1.9376 (49,194–49,215) Rod Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0005–.002 (0,013–0,051) Main & Rod Bearing Journal– Max. Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0003 (0,008) Max. Out–of–Round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0004 (0,010) Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .003–.011 (0,08–0,28) Bearing Wall Thickness–Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0719–.0722 (1,788–1,796) For every .002 (0,051) undersized thickness add .001 (0,026) to standard thickness.

Crankshaft Thrust Washer (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.091–0.093 (2,31–2,36 mm) Other Thickness Available . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002–0.005–0.007–0.010 (0,051–0,127–0,118–1,254 mm) The crankshaft and cylinder block are color–coded for installation of the correct bearings AT THE FACTORY. Use a micrometer to measure the inside diameter and the outside diameter of the bearing surfaces so that correct replacement bearings can be ordered.

8C–1.7 Connecting Rod Piston Pin Bushing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8121–.8125 (20,627–20,638) Connecting Rod Bearing Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0825–2.0830 (52,90–52,91) Connecting Rod Length Center to Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9265–4.9295 (125,133–125,209) Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .004–.010 (0,10–0,25) Max. Twist or Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .004 (0,10) Pin bushing and crankshaft bearing bore must be parallel and in the same vertical plane within the specified total difference at ends of 8–inch long bar measure 4 inches on each side of rod.

8C–1.8 Piston Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1853–3.1877 (80,907–80,967)Piston to Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . .0016–.0025 (0,04064–0,06350) (Measure 90° to pin centerline and at bottom of pin) (Clearance 90° to pin centerline and at bottom of pin) Clearance Between Deck and Piston Crown at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .025–.043 (0,63–1,09) 8C–1.9 Piston Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8119–.8123 (20,622–20,632) Interference Fit in Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0001–.0003 (0,003–0,008) Clearance in Rod Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0001–.0003 (0,003–0,008) 8C–1.10 Piston Rings Top Compression Ring Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0615–.0625 (1,56–1,59) Bottom Compression Ring Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .077–0.78 (0,0003–0,008) Top Clearance Ring Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0026–.0036 (0,041–0,091) Bottom Compression Ring Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0016–.0036 (0,041–0,091) Compression Ring Side Clearance–Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 (0,152) Oil Ring Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155–.156 (3,94–3,96) Oil Ring Side Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0018–.0038 (0,046–0,097) Oil Ring Side Clearance–Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .007 (0,178) Top Compression Ring–Std. Bore–Ring Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .008–.014 (0,23–0,36) Bottom Compression Ring–Std. Bore–Ring Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .009–.014 (0,23–0,36) Oil Ring–Std. Bore–Ring Gap Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .009–.014 (0,23–0,36)

Revised Mar. 85

–8C–4–

630, 631, 632 Loader Service Manual

8C–1.11 Cylinder Block Cylinder Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1869–3.1893 (80,948–81,008) Cylinder Bore Out–of–Round–Max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0015 (0,038) Taper–Max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .001 (0,025) Tappet Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .516–.517 (13,11–13,13) Main Bearing Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2710–2.2715 (57,683–57,696) Height, Pan Surface to Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.326–8.331 (211,48–211,61) Gasket Surface Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .003 (0,076) In Any 6 Inches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 (0,152) Max. Overall

8C–1.12 Ignition System Distributor Point Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .025 (0,64) Dwell Angel (Under 700 RPM) W/Vacuum Line Connected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48°–52° Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2 – 4 – 3 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Counterclockwise Initial Timing–BTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12° End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preload Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AGR–22 Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .026–.028 (0,66–0,71) Coil–Primary Resistance (Ohms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40–1.54 (75°F) Secondary Resistance (Ohms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7600–8800 (75°F) Primary External Resistance (Ohms) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30–1.40 (75°F) Condenser–(Micron Farads) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.21–0.25 High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2600–2675 RPM Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850–950 RPM

DISTRIBUTOR ADVANCE CHARACTERISTICS* ENGINE RPM

CENTRIFUGAL PLUS INITIAL ADVANCE

CENTRIFUGAL PLUS VACUUM PLUS INITIAL ADVANCE

850 1000 1200 1400 1600 2000 2600

10–12° 10–12° 10–15° 11–17° 13–19° 18–24° 22–28°

28–36° 28–36° 28–39° 29–41° 31–43° 36–48° 40–52°

*All above values are readings as seen at crankshaft timing marks.

8C–1.13 Starter Solenoid Actuated Starter Motor Dia. In Inches (Metric) 3–1/2 (88,9)

Revised Mar. 85

Current Draw Under Normal Load (Amps) 135–250

Starter Brushes

Normal Engine Cranking Speed (RPM) 140–180

–8C–5–

No. Load (Amps) 65

Wear Limit In Inches 5/16 (1,8)

Spring Tension (Ounces 28

630, 631, 632 Loader Service Manual

8C–1.14 Torque Specifications for Engine Item Camshaft Sprocket to Camshaft Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft Thrust Plate Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rod Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Pulley Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Front Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carburetor Attaching Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain Tension Support to Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Distributor to Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Distributor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Manifold to Cylinder Head Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Separator Clamping Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel to Crankshaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pump to Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator Mounting to Cylinder Block Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intake Manifold to Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Bearing Cap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pump to Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pan to Cylinder Block Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pump Cover to Oil Pump Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Oil Seal Retainer to Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rocker Cover to Cylinder Head Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rocker Shaft Support Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug to Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water Outlet Connection to Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water Pump to Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water Pump to Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ft.–Lbs. 12–15 2.5 30–35 Step 1–20–30 Step 2–50–55 Step 3–65–70 24–28 5–7 12–15

Nm 16–20 3.5 41–47 27–41 68–75 88–95 33–38 7–9,5 16–20

5–7 5–7 2–3

7–9,5 7–9,5 2,7–4,1

15–18 6–9 45–50 12–15

20–24 8–12 61–68 16–20

20–25

27–34

15–18 65–70 12–15 20–25 6–8 5–7

20–24 88–95 16–20 27–34 8–11 7–9,5

12–15

16–20

2.5–3.5 25–30 22–28

3,4–4,7 34–41 30–38

12–15 5–7 12–15 1/2 turn after gasket contacts surface

16–20 7–9,5 16–20

8C–1.16 Special Tools (Ford) T64P–3590–F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Puller T70P–6046–A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor–Valve Spring T70P–6150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installer–Aligner–Front Cover Seal T70P–6165 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installer–Crankshaft Rear Seal T70P–6250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remover–Installer–Camshaft Bearings Tool–6505–G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Stem Clearance Checking Tool Tool–6513–DD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Spring Tester C8AZ–6B627–A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankcase Ventilation System Tester T63L–8620A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Tension Gauge Carburetor Tool C161–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Discharge Wrench C161–10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plug Wrench C161–25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft Nut Wrench C161–71–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bushing Line Reamer C161–72–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bushing Driver C161–82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Valve Seat Wrench C161–83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Jet Wrench

–8C–6–

630, 631, 632 Loader Service Manual

TECHNICAL DATA Paragraph Number DECIMAL & MILLIMETER EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC/HYDROSTATIC TRANSMISSION FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOADER TORQUE SPECIFICATIONS . . . . . . . . . . . . . . .

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STANDARD TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . . . . .

–8D––1–

Page Number 8D–3

8D–2 8D–1 8D–3

8D–1 8D–1 8D–1 8D–2 8D–3

TECHNICAL DATA

630, 631, 632 Loader Service Manual

–8D–0–

630, 631, 632 Loader Service Manual

8D–1 LOADER TORQUE SPECIFICATIONS The following special torques must be used on Bobcat loader.

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55–65 ft.–lbs. (75–88 Nm) Axle Sprocket Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210–225 ft.–lbs. (285–305 Nm) Hydrostatic Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–50 ft.–lbs. (54–68 Nm) Engine Mounting Bolts (Engine–To–Mount) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65–70 ft.–lbs. (88–95 Nm) (Mount–To–Frame) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125–140 ft.–lbs. (170–190 Nm) ROPS Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–50 ft.–lbs. (54–88 Nm) Steering Linkage Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tighten bolt until spring is 2.48–2.72” (62,99–69–08 mm) long with levers in neutral position Hydraulic Cylinder Piston Nuts Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195–205 ft.–lbs. (264–278 Nm) Tilt Cylinder (Cushioned) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330–360 ft.–lbs. (447–488 Nm) Hydrostatic Motor Sprocket Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300–400 ft.–lbs. (407–542 Nm) Hydrostatic Motor Mounting Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100–110 ft.–lbs. (135–149 Nm) Hydraulic Pump to Hydrostatic Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54–66 ft.–lbs. (73–89 Nm) Main Frame to Upright Frame Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65–70 ft.–lbs. (88–95 Nm) (Flangehead) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90–100 ft.–lbs. (122–136 Nm) Pump Coupler to Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215–240 in.–lbs. (24–27 Nm) Pump Coupler Assembly Bolts (12 pt.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270–300 in.–lbs. (31–34 Nm) Bob–Tach to Lift Arm Pivot Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125–140 ft.–lbs. (170–190 Nm) Hydrostatic Pump Spline (Drive) Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–25 ft.–lbs. (27–34 Nm) 8D–2 HYDRAULIC/HYDROSTATIC TRANSMISSION FLUID The hydraulic system capacity is 6 gallons (22,7 liters). The transmission reservoir capacity is 5 gallons (18,9 liters) when filled to check plug.

Use Clark hydraulic/hydrostatic transmission fluid. If this fluid (P/N 6563328) is not available, 10W30 or 10W–40 engine oil may be used.

IMPORTANT:

DO NOT USE automatic transmission fluids in this machine or permanent damage to the transmission will result. Where below zero temperatures are common, machines 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 hydraulic components slower. Loss of oil flow to hydrostatic transmission pump (indication by “TRANS” light on) will cause transmission damage in less than 60 seconds time).

8D–2.1 Hydrostatic System Specifications Motor (Ross) Shaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .005–.025” (0,127–0,635 mm) Motor (Ross) Shaft Side Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006–.010” (0,152–0,254 mm) 8D–3 SPECIAL TOOLS (Also See Tool Catalog [P/N 6556519]) 8D–3.1 Main Frame & Hydraulic Tools Chain Breaker Tool (Size No. 40 thru 60 Chain) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6514802 Chain Breaker Tool (Size No. 60 thru 80 Chain) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6514843 Hydraulic Cylinder Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6598090 and 4127913 Boom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Parts Manual Y–90 Tester & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Parts Manual Axle Seal Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6558009 Wrench for Motor Sprocket Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6559551 Hydraulic Cylinder Seal Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6562764 8D–3.2 Hydrostatic System Tools Pilot Bearing Puller, Capacity 1/2” to 1–1/2” ID Hydrostatic Motor Seal Installation Tool 1–1/4” Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6561729 (Ross) 1–1/2” Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6562096 (Ross) 6598482 and 6598481 (Char–Lynn) Snap Ring Plier Set

Revised Mar. 85

–8D–1–

630, 631, 632 Loader Service Manual

CONVERSIONS Decimal And Millimeter Equivalents FRACTIONS

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

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

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

FRACTIONS

DECIMALS 33/64

17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1

1 mm = 0.03937’’

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

— — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — —

MM 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

MULTIPLY BY

LINEAR MEASUREMENT

Miles Yards Feet Feet Inches Inches Inches

Kilometers Meters Meters Centimeters Meters Centimeters Millimeters

AREA

Square Miles Square Feet Square Inches Acre

Square Kilometers Square Meters Square Centimeters Hectare

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–Metre

1.356

LIQUID VOLUME

Quarts Gallons

Liters Liters

0.9463 3.785

LIQUID FLOW

Gallons/Minute

Liters/Minute

3.785

TEMPERATURE

Fahrenheit

Celsius

1.609 0.9144 0.3048 30.48 0.0254 2.54 25.4 2.59 0.0929 6.452 0.4047

1.Subtract 32° 2. Multiply by 5/9 –8D–2–

630, 631, 632 Loader Service Manual

ALPHABETICAL INDEX Paragraph Number ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–1

Page Number 9–1

ALPHABETICAL INDEX

–9––1–

630, 631, 632 Loader Service Manual

–9–0–

630, 631, 632 Loader Service Manual

9 ALPHABETICAL INDEX Subject

Subject

Page

Page

Crankshaft End Play (632) . . . . . . . . . . . . . . . . . . . 7C–10 Crankshaft Inspection, F2L411D (631) . . . . . . . . . 7B–18 Crankshaft Inspection, F2L511D (631) . . . . . . . . . 7B–39 Crankshaft, installation of (630) . . . . . . . . . . . . . . . . 7A–9 Crankshaft Journals, reconditioning (632) . . . . . . . 7C–11 Crankshaft, removal of (630) . . . . . . . . . . . . . . . . . . . 7A–9 Crankshaft Removal, F2L411D (631) . . . . . . . . . . . 7B–18 Crankshaft Removal, F2L511D (631) . . . . . . . . . . . 7B–38 Crankshaft Sprockets (632) . . . . . . . . . . . . . . . . . . 7C–21 Crankshaft, three bearing (630) . . . . . . . . . . . . . . . . 7A–9 Cylinder Block (632) . . . . . . . . . . . . . . . . . 7C–13, 7C–15 Cylinder Block, installation of (630) . . . . . . . . . . . . 7A–10 Cylinder Block, removal of (630) . . . . . . . . . . . . . . . . 7A–8 Cylinder Head (632) . . . . . . . . . . . 7C–10, 7C–13, 7C–18 Cylinder Head, installation of (630) . . . . . . . . . . . . . 7A–12 Cylinder Head, installation of F2L411D (631) . . . . 7B–11 Cylinder Heads, removal of (630) . . . . . . . . . . . . . . . 7A–6 Cylinder Head & Valves, F2L411D (631) . . . . . . . . . 7B–8 Cylinder Head & Valve, F2L511D (631) . . . . . . . . . 7B–28 Cylinders, Pistons & Connecting Rods, F2L411D (631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–12 Cylinders, Pistons & Connecting Rods, F2L511D (631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–32

Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 Air Housing, installation of (630) . . . . . . . . . . . . . . . 7A–13 Air Housing, removal of (630) . . . . . . . . . . . . . . . . . . 7A–6 Alternator Assembly & Installation . . . . . . . . . . . . . . 6–26 Alternator Belt, adjustment & replacement . . . . . . . 6–23 Alternator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6–24 Alternator Output, check . . . . . . . . . . . . . . . . . . . . . . 6–24 Alternator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–24 Alternator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–24 Alternator Wiring, check . . . . . . . . . . . . . . . . . . . . . . . 6–23 Axle Assembly & Installation . . . . . . . . . . . . . . . . . . . . 4–2 Axles & Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 Axle & Bearing, removal . . . . . . . . . . . . . . . . . . . . . . . . 4–1 Battery & Cables, check condition of . . . . . . . . . . . . 6–23 Battery, installing new . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 Battery, using an extra . . . . . . . . . . . . . . . . . . . 1–13, 6–1 Bearings, camshaft (632) . . . . . . . . . . . . . . . . . . . . 7C–30 Bearings, connecting rods (632) . . . . . . . . . . . . . . 7C–27 Bearings, main (632) . . . . . . . . . . . . . . . . . . . . . . . . 7C–26 Bearings, Main & Connecting Rod (632) . . . . . . . 7C–15 Blower Fan, F2L411D (631) . . . . . . . . . . . . . . . . . . . . 7B–8 Blower Fan, F2L511D (631) . . . . . . . . . . . . . . . . . . . 7B–27 Bob–Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Bob–Tach Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 Bob–Tach Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Bob–Tach Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Bob–Tach & Pivot Pins . . . . . . . . . . . . . . . . . . . . . . . . 1–16 Bob–Tach Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Bob–Tach Wedges, checking . . . . . . . . . . . . . . . . . . . 5–2 Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 Breather, crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 Brush Replacement (Starter) . . . . . . . . . . . . . . . . . . . 6–28 By–Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18

Detent Spool, repair . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10 Diode Trio, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 6–25 Distributor Maintenance . . . . . . . . . . . . . . . . . . . . . . . 7A–4 Drive Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 Drive, final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

Camshaft (632) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–14 Camshaft, F2L411D (631) . . . . . . . . . . . . . . . . . . . . 7B–17 Camshaft, F2L511D (631) . . . . . . . . . . . . . . . . . . . . 7B–38 Camshaft End Play (632) . . . . . . . . . . . . . . . . . . . . 7C–10 Camshaft, installation of (630) . . . . . . . . . . . . . . . . . . 7A–9 Camshaft Gear, installation of (630) . . . . . . . . . . . . 7A–12 Camshaft, removal of (630) . . . . . . . . . . . . . . 7A–6, 7A–9 Camshaft Repair (632) . . . . . . . . . . . . . . . . . . . . . . . 7C–11 Camshaft & Valve Lifters (632) . . . . . . . . . . . . . . . 7C–23 Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 1–10 Carburetor & Manifold, installation of (630) . . . . . . 7A–13 Carburetor & Manifold, removal of (630) . . . . . . . . . 7A–6 Carburetor Repair (632) . . . . . . . . . . . . . . . . . . . . . . . 7C–9 Carburetor Service (630) . . . . . . . . . . . . . . . . . . . . . . 7A–5 Carburetor, Throttle & Governor Adjustment (632) 7C–4 Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 Connecting Rod (632) . . . . . . . . . . . . . . . . . . . . . . . 7C–14 Connections, 37° Flare . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 Connection, straight thread o–ring . . . . . . . . . . . . . . . 2–7 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 Control Valve, assembling . . . . . . . . . . . . . . . . . . . . . . 2–9 Control Valve, disassembly & inspection of . . . . . . . . 2–9 Control Valve, removing . . . . . . . . . . . . . . . . . . . . . . . . 2–9 Crankshaft (632) . . . . . . . . . . . . . . 7C–11, 7C–14, 7C–29 Crankshaft Assembly, F2L411D (631) . . . . . . . . . . 7B–18 Crankshaft Assembly, F2L511D (631) . . . . . . . . . . 7B–39 Crankshaft Connecting Rod Bearing, to check (632)7C–11

Electrical Circuit (631, 632) . . . . . . . . . . . . . . . . . . . . 6–21 Electrical Connector, ROPS . . . . . . . . . . . . . . . . . . . . 6–22 Electrical General Information . . . . . . . . . . . . . . . . . . 6–19 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 Electrical Wiring, check . . . . . . . . . . . . . . . . . . . . . . . 6–28 Engine Compression, checking (632) . . . . . . . . . . . 7C–3 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . 1–10 Engine Diagnosis & Testing (632) . . . . . . . . . . . . . . . 7C–9 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . 1–11 Engine Front Cover, F2L411D (631) . . . . . . . . . . . . 7B–14 Engine Front Cover, F2L511D (631) . . . . . . . . . . . . 7B–34 Engine Front Cover (632) . . . . . . . . . . . . . . . . . . . . 7C–21 Engine Ignition System (630) . . . . . . . . . . . . . . . . . . 7A–4 Engine Information, F2L411D (631) . . . . . . . . . . . . . 7B–7 Engine Information, F2L511D (631) . . . . . . . . . . . . 7B–27 Engine Mounts, F2L411D (631) . . . . . . . . . . . . . . . . 7B–2 Engine Mounts, F2L511D (631) . . . . . . . . . . . . . . . 7B–21 Engine Muffler, the . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 Engine Oil & Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 Engine Oil Pressure (632) . . . . . . . . . . . . . . . . . . . . . 7C–2 Engine Overhaul (632) . . . . . . . . . . . . . . . . . . . . . . 7C–10 Engine, removal of (630) . . . . . . . . . . . . . . . . . . . . . . 7A–5 Engine Removal, F2L411D (631) . . . . . . . . . . . . . . . 7B–7 Engine Removal, F2L511D (631) . . . . . . . . . . . . . . 7B–27 Engine, removal of (632) . . . . . . . . . . . . . . . . . . . . 7C–16 Engine Service (General) . . . . . . . . . . . . . . . . . . . . . . . 1–4 Engine Service (630) . . . . . . . . . . . . . . . . . . . . . . . . . 7A–1 Engine Service, F2L411D (631) . . . . . . . . . . . . . . . . 7B–1 Engine Service, F2L511D (631) . . . . . . . . . . . . . . . 7B–20 Engine Service Ford Engine (632) . . . . . . . . . . . . . . 7C–1 Filter Housing, F2L411D (631) . . . . . . . . . . . . . . . . 7B–14

–9–1–

630, 631, 632 Loader Service Manual

9 ALPHABETICAL INDEX (Cont’d) Subject

Page

Float Adjustment (630) . . . . . . . . . . . . . . . . . . . . . . . . 7A–5 Flywheel (632) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–14 Flywheel, F2L411D (631) . . . . . . . . . . . . . . . . . . . . . 7B–19 Flywheel, F2L511D (631) . . . . . . . . . . . . . . . . . . . . . 7B–40 Flywheel Face Alignment, check (632) . . . . . . . . . 7C–10 Flywheel, installation of (630) . . . . . . . . . . . . . . . . . 7A–13 Flywheel, removal of (630) . . . . . . . . . . . . . . . . . . . . . 7A–6 Flywheel Ring Gear (632) . . . . . . . . . . . . . . . . . . . . 7C–25 Fuel & Control Linkage Adjustment, F2L411D (631) 7B–3 Fuel Delivery, adjustment of F2L411D (631) . . . . . . 7B–6 Fuel Delivery, adjustment of F2L511D (631) . . . . . 7B–25 Fuel Filter, F2L411D (631) . . . . . . . . . . . . . . . . . . . . . 7B–4 Fuel Filter, F2L511D (631) . . . . . . . . . . . . . . . . . . . . 7B–22 Fuel Injection Nozzles, F2L411D . . . . . . . . . . . . . . . 7B–7 Fuel Injector Nozzles, F2L511D (631) . . . . . . . . . . 7B–26 Fuel Injection Nozzles, disassembly & repair F2L411D (631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–7 Fuel Injection Nozzles, installation of F2L411D (631)7B–7 Fuel Injection Nozzles, removal of F2L411D (631) 7B–7 Fuel Injection Pump, F2L411D (631) . . . . . . . . . . . . 7B–5 Fuel Injection Pump, F2L511D (631) . . . . . . . . . . . 7B–23 Fuel Injection Pump, removal of F2L511D (631) . . 7B–5 Fuel Injection, removal of F2L511D (631) . . . . . . . 7B–23 Fuel Injection Pump Service, F2L411D (631) . . . . . 7B–5 Fuel Injection Pump Service F2L511D (631) . . . . 7B–23 Fuel Injection Pump, to install F2L411D (631) . . . . 7B–5 Fuel Injection Pump, to install F2L511D (631) . . . 7B–23 Fuel Lift Pump, F2L411D . . . . . . . . . . . . . . . . . . . . . . 7B–4 Fuel Lift Pump, F2L511D . . . . . . . . . . . . . . . . . . . . . 7B–23 Fuel Shut–Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 Fuel System (630, 632) . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 Fuel System, F2L411D (631) . . . . . . . . . . . . . . . . . . . 7B–3 Fuel System, F2L511D (631) . . . . . . . . . . . . . . . . . . 7B–21 Fuel System (General) (631) . . . . . . . . . . . . . . . . . . . . . 1–9 Fuel System, venting air from, F2L411D (631) . . . . 7B–3 Fuel System, venting air from, F2L511D (631) . . . 7B–22 Gear Cover, installation of (630) . . . . . . . . . . . . . . . 7A–12 Gear Cover, removal of (630) . . . . . . . . . . . . . . . . . . 7A–6 Governor Adjustment (630) . . . . . . . . . . . . . . . . . . . . 7A–5 Governor, F2L411D (631) . . . . . . . . . . . . . . . . . . . . 7B–16 Governor, F2L511D (631) . . . . . . . . . . . . . . . . . . . . 7B–37 Governor Service (630) . . . . . . . . . . . . . . . . . . . . . . 7A–13 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 Hydraulic Cylinder, removing . . . . . . . . . . . . . . . . . . . . 2–12 Hydraulic Cylinder, repair . . . . . . . . . . . . . . . . . . . . . . . 2–13 Hydraulic Fluid & Filter . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 Hydraulic Pump Replacement . . . . . . . . . . . . . . . . . . . 2–11 Hydraulic System Information . . . . . . . . . . . . . . . . . . . . 2–7 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13 Hydrostatic Motors (630&632S/N15320& Below) . . 3–26 Hydrostatic Motor Assembly (630 & 632 S/N 15320 & Below) . . . . . . . . . . . . . . . . . . . . . . . . . . 3–32 Hydrostatic Motor Assembly (631 & 632 S/N 15321 & Above . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38 Hydrostatic Motor Disassembly (630 & 632 S/N 15321 & Above . . . . . . . . . . . . . . . . . . . . . . . . . . 3–36 Hydrostatic Motor Disassembly & Inspection (630 & 632 S/N 15320 & Below) . . . . . . . . . . . . . . . . 3–31

Subject

Page

Hydrostatic Motor Inspection (631 & 632 S/N 15321 & Above) . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic Motor, installing (630 & 632 S/N 15320 & Below) . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic Motors, removing the (630 & 632 S/N 15320 & Below) . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic Motor, repair (630 & 632 S/N 15320 & Below) . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic Motor, repair (631 & 632 S/N 15321 & Above) . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic Motor, start–up procedure . . . . . . . . . . .

Hydrostatic Pump Assembly, repair . . . . . . . . . . . . .

Hydrostatic Pump Disassembly . . . . . . . . . . . . . . . .

Hydrostatic Pump Inspection . . . . . . . . . . . . . . . . . . .

Hydrostatic System, to remove air from . . . . . . . . .

3–38 3–27 3–26 3–30 3–36 3–35 3–19 3–19 3–20 3–29

Idler Gear & Shaft, installation of (630) . . . . . . . . . 7A–12 Idler Gear & Shaft, removal of (630) . . . . . . . . . . . . 7A–7 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 Ignition System (632) . . . . . . . . . . . . . . . . . . . . . . . . . 7C–6 Ignition System Tests (632) . . . . . . . . . . . . . . . . . . . . 7C–7 Ignition Timing (632) . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–8 Inspecting, 30–hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Inspection, pre–delivery . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Intake Manifold (632) . . . . . . . . . . . . . . . . . . . . . . . 7C–18 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 Lift Arms, pivot pin replacement . . . . . . . . . . . . . . . . . 5–1 Lift Cylinder, checking . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 Lubrication, loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16 Main Frame To Upright Frame Bolts . . . . . . . . . . . . . 5–3 Oil Cooler, engine F2L511D (631) . . . . . . . . . . . . . 7B–40 Oil Pan (632) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–25 Oil Pan, installation (630) . . . . . . . . . . . . . . . . . . . . . . 7A–9 Oil Pan, removal of (630) . . . . . . . . . . . . . . . . . . . . . . 7A–7 Oil Pump (632) . . . . . . . . . . . . . . . . . . . . . . 7C–16, 7C–26 Oil Pump, Filter Housing & Relief Valve F2L411D (631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–13 Oil Pump, Filter Housing & Relief Valve F2L511D (631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–34 Oil Pump, installation of (632) . . . . . . . . . . . . . . . . . 7A–11 Oil Pump, removal of (630) . . . . . . . . . . . . . . . . . . . . 7A–7 Oil Seal Crankshaft Rear (632) . . . . . . . . . . . . . . . 7C–26 Oil Seal, front (632) . . . . . . . . . . . . . . . . . . . . . . . . . 7C–23 Pistons & Connecting Rods (632) . . . . . . . . . . . . . 7C–27 Pistons & Connecting Rods, installation of (630) . 7A–10 Pistons & Connecting Rods, removal of (630) . . . . 7A–7 Pistons, Pins & Rings (632) . . . . . . . . . . . . . . . . . . 7C–12 Piston Rings, installation of (630) . . . . . . . . . . . . . . 7A–10 Pump Assembly, #1 . . . . . . . . . . . . . . . . . . . . . . . . . . 3–24 Pump Assembly, #2 . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23 Pump Assembly, removal & installation . . . . . . . . . . 3–18 Pumps To Manifold Block, installing . . . . . . . . . . . . . 3–25 Quick–Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17 Quick–Couplers, restriction in the . . . . . . . . . . . . . . . 2–17 Rectifier, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–25

–9–2–

630, 631, 632 Loader Service Manual

9 ALPHABETICAL INDEX (Cont’d) Subject

Page

Rectifier Module, to check the . . . . . . . . . . . . . . . . . . . 6–21 Regulator, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–24 Regulator Module, to check the . . . . . . . . . . . . . . . . . 6–21 Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10 Relief Valve, oil pressure F2L411D (631) . . . . . . . 7B–14 Relief Valve, oil pressure F2L511D (631) . . . . . . . 7B–34 Replenishing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17 Replenishing Valves, checking . . . . . . . . . . . . . . . . . . 3–17 ROPS, removal & installation . . . . . . . . . . . . . . . . . . . . 5–1 Rotor, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–25

Subject

Page

Valve Rocker Arm (632) . . . . . . . . . . . . . . . . . . . . . 7C–17 Valve & Seat Inserts, removal of (630) . . . . . . . . . . 7A–8 Valve Seat, grinding (632) . . . . . . . . . . . . . . . . . . . . 7C–11 Valves & Seat Inserts, installation of (632) . . . . . . 7A–10 Valve Spring (632) . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–20 Valve Tappets, installation of (632) . . . . . . . . . . . . . . 7A–9 Valve Tappets, removal of (632) . . . . . . . . . . . . . . . . 7A–9 Water Pump (632) . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–21 Yoke, Pintle Bearing, etc., installation . . . . . . . . . . . 3–21

Serial Number, engine . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Serial Number Identification . . . . . . . . . . . . . . . . . . . . . . 1–1 Serial Number, loader . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Spark Plugs (630) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–4 Specifications, engine (630) . . . . . . . . . . . . . . . . . . . . 8A–2 Specifications, engine F2L511D (631) . . . . . . . . . . . 8B–5 Specifications, engine (632) . . . . . . . . . . . . . . . . . . . . 8C–2 Specifications, loader (630) . . . . . . . . . . . . . . . . . . . . 8A–1 Specifications, loader (631) . . . . . . . . . . . . . . . . . . . . 8B–1 Specifications, loader (632) . . . . . . . . . . . . . . . . . . . . 8C–1 Specifications, loader torque . . . . . . . . . . . . . . . . . . . 8D–1 Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–28 Starter, disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–26 Starter, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–26 Starter, removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–26 Stator, (Alternator) checking . . . . . . . . . . . . . . . . . . . . 6–25 Stator, (Flywheel Alternator) to check the . . . . . . . . . 6–20 Steering Linkage Adjustment . . . . . . . . . . . . . . . . . . . . 3–16 Steering Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–41 Steering Linkages, installing (630 S/N 15300 & Below) (631 S/N 12253 & Below (632 S/N 15450 & Below) . . . . . . . . . . . . . . . . . . . . . . . 3–41 Steering Linkages, installing (630 S/N 15301 & Above) (631 S/N 12254 & Above) (632 S/N 15451 & Above) . . . . . . . . . . . . . . . . . . . . . . 3–43 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 Tappet (632) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–14 Tilt Cylinder, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12 Tilt Cylinder, Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17 Timing Chain (632) . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–21 Timing Chain, tightener (632) . . . . . . . . . . . . . . . . . 7C–23 Timing Procedure (630) . . . . . . . . . . . . . . . . . . . . . . . 7A–4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15 Tools, special . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D–1 Tubelines & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 Transmission & Drive System . . . . . . . . . . . . . . . . . . . 1–15 Troubleshooting, electrical . . . . . . . . . . . . . . . . . . . . . . 6–21 Troubleshooting, the flywheel alternator . . . . . . . . . . 6–19 Troubleshooting, hydraulic . . . . . . . . . . . . . . . . . . . . . . . 2–8 Troubleshooting, hydrostatic . . . . . . . . . . . . . . . . . . . . 3–13 Troubleshooting, Deutz F2L411D (631) . . . . . . . . . . 7B–1 Troubleshooting, Deutz F2L511D (631) . . . . . . . . . 7B–20 Troubleshooting, Ford Engine (632) . . . . . . . . . . . . . 7C–1 Troubleshooting, Wisconsin Engine (630) . . . . . . . . 7A–3 Valves (632) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–11 Valve Clearance (632) . . . . . . . . . . . . . . . . . . . . . . . . 7C–2 Valve Guides (632) . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–10 Valve Pushrod (632) . . . . . . . . . . . . . . . . . . . . . . . . . 7C–17

–9–3–

630, 631, 632 Loader Service Manual

–9–4–

630, 631, 632 Loader Service Manual

630–1 ®

Revision Number

18 August 1983

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT Model

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

630, 631, 632

X

Manual No. 6556454 (4–81)

This Service Manual Revision adds the procedure to replace the dust and inner seal, in the mounting flange, for Motor (P/N 6599718) Model No. 109–1052–006.

Remove pages 3–35 thru 3–44.

Add Pages (Revised Aug. 83) 3–36 thru 3–44 and (Added Aug. 83) 3–45 thru 3–48.

Printed in U.S.A.

–5

–4

630–2 ®

Revision Number

31 January 1985

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT LOADER Model

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

630 SERIES

X

Manual No. 6556454 (4–81)–2M

The attached pages are a revision to the Service Manual. Please replace existing pages with the new pages as follows:

TAKE OUT

PUT IN

3–45 Added Aug. 83 3–46 Added Aug. 83

3–45 Revised Jan. 85 3–46 Added Aug. 83

Printed in U.S.A.

–3

–2

630–3 ®

Revision Number

31 March 1985

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT LOADER Model

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

630, 631, 632

X

Manual No. 6556454 (4–81)–2M

The attached pages are a revision to the Service Manual. Please replace existing pages with the new pages as follows:

TAKE OUT

PUT IN

2–7, 2–8

2–7 (Revised Mar. 85), 2–8

3–19, 3–20 3–25, 3–26 3–31, 3–32 3–33, 3–34 3–35, 3–36 (Revised Aug. 83) 3–37 (Revised Aug. 83, 3–38 (Revised Aug. 83)

3–19 (Revised Mar. 85), 3–20 3–25 (Revised Mar. 85), 3–26 (Revised Mar. 85) 3–31, 3–32 (Revised Mar. 85) 3–33, 3–34 (Revised Mar. 85) 3–35 (Revised Mar. 85), 3–36 (Revised Aug. 83) 3–37 (Revised Mar. 85), 3–38 (Revised Aug. 83)

4–1, 4–2

4–1 (Revised Mar. 85), 4–2 (Revised Mar. 85)

6–19, 6–20 6–21, 6–22 6–25, 6–26

6–19, 6–20 (Revised Mar. 85) 6–21 (Revised Mar. 85), 6–22 6–25 (Revised Mar. 85), 6–26 (Revised Mar. 85)

7B–15, 7B–16 7B–17, 7B–18 7B–37, 7B–38 7B–39, 7B–40

7B–15 (Revised Mar. 85), 7B–16 7B–17, 7B–18 (Revised Mar. 85) 7B–37, 7B–38 (Revised Mar. 85) 7B–39, 7B–40 (Revised Mar. 85)

8A–1, 8A–2

8A–1 (Revised Mar. 85), 8A–2 (Revised Mar. 85)

8B–1, 8B–2 8B–3, 8B–4 8B–5, 8B–6 8B–7

8B–1 (Revised Mar. 85), 8B–2 (Revised Mar. 85) 8B–3 (Revised Mar. 85), 8B–4 (Revised Mar. 85) 8B–5 (Revised Mar. 85), 8B–6 (Revised Mar. 85) 8B–7 (Revised Mar. 85)

8C–1, 8C–2 8C–3, 8C–4 8C–5, 8C–6

8C–1 (Revised Mar. 85), 8C–2 (Revised Mar. 85) 8C–3 (Revised Mar. 85), 8C–4 (Revised Mar. 85) 8C–5 (Revised Mar. 85), 7C–6

8D–1, 8D–2

8D–1 (Revised Mar. 85), 8D–2

Printed in U.S.A.

–1

0

630–4 ®

Revision Number

22 March 1988

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT LOADER Model

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

630 SERIES

X

Manual No. 6556454 (4–81)–2M

The attached pages are a revision to the Service Manual. Please replace existing pages with the new pages as follows: These pages update the Deutz F2L511 Engine Spec. Section.

TAKE OUT

PUT IN

8B–5 (Revised Mar. 85), 8B–6 (Revised Mar. 85)

8B–5 (Revised Mar. 88), 8B–6 (Revised Mar. 88)

Printed in U.S.A.

i

ii