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

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This workshop repair service manual PDF download for the 600, 600D, 610, 611 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Loader 600
Bobcat Loader 600D
Bobcat Loader 610
Bobcat Loader 611

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

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

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

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MAINTENANCE SAFETY
CONTENTS
FOREWORD

GENERAL SERVICE
SERVICE SCHEDULE
TIRES
LOADER LUBRICATION
CHANGING AND ADDING HYDRAULIC OIL
REMOVING WATER FROM HYDRAULIC TANKS
BOB–TACH FRAME
HYDRAULIC FLUID FILTERCHANGE
ENGINE AIR CLEANER
OIL TYPE AIR CLEANER
HEAVY DUTY AIR CLEANER
ENGINE OIL
OIL SPECIFICATIONS FOR ENGINES
ENGINE OIL FILTER (Wisconsin)
ENGINE OIL FILTER (Duetz Diesel)
OIL FILTER (Petter)
CRANKCASE AIR VENT (Wisconsin)
CRANKCASE AIR VENT (Deutz)
FUEL SPECIFICATIONS
FUEL FILTER
EXCESS FUEL LEVER ADJUSTMENT (Deutz Engine)
FUEL PUMP (Wisconsin)
FUEL ADJUSTMENT (Petter)
ENGINE COOLING SYSTEM
WATER SCRUBBER MUFFLER (600 Diesel)
IGNITION TIMING (Wisconsin Engine)
DISTRIBUTOR MAINTENANCE (Wisconsin)
SPARK PLUG (Wisconsin)
ELECTRICAL SYSTEMS
CHECKING REGULATOR AND RECTIFIER
STATOR CHECKS
ALTERNATOR CHECK
REGULATOR CHECK #1
REGULATOR CHECK #2
REGULATOR CHECK #3

TROUBLESHOOTING
TROUBLESHOOTING THE DRIVE SYSTEM
TROUBLESHOOTING THE HYDRAULIC SYSTEM
TROUBLESHOOTING THE ENGINE

DRIVE SYSTEM
CLUTCH ADJUSTMENT
Adjustment Procedure
Steering Clutch Adjustment
DISASSEMBLY & ASSEMBLY
Disassembly
Assembly
INSTALLING CLUTCH NEEDLE BEARINGS.
DRIVE BELT INSTALLATION (Split Shaft)
REMOVAL OF DRIVEN SHEAVE
INSTALLING OF DRIVEN SHEAVE
DRIVEN SHEAVE DISASSEMBLY
ASSEMBLY OF DRIVEN SHEAVE (TAPERED JACKSHAFT)
DISASSEMBLY OF DRIVE SHEAVE (STRAIGHT JACKSHAFT)
ASSEMBLY OF DRIVEN SHEAVE (STRAIGHT JACKSHAFT)
DRIVEN SHEAVE ALIGNMENT
JACKSHAFT BEARING INSTALLATION
REMOVAL OF VARIABLE DRIVE SHEAVE WITH ROTO SWIVEL INSIDE (600, 610 Gasoline and Diesel, Serial Number 72319 and Up)
ROTO–SWIVEL DISASSEMBLY
ROTO–SWIVEL ASSEMBLY
ASSEMBLY PROCEDURES FOR 610 VARIABLE SPEED WITH ROTO–SWIVEL INSIDE
REMOVAL OF VARIABLE SHEAVE WITH ROTO–SWIVEL OUTSIDE (600 Gasoline, LP and Diesel; Serial Number 67253–72318)
REMOVAL OF FRAME SUPPORT VARIABLE SHEAVE (600 Gasoline and LP; serial Number 62796–67252)
AXLE REMOVAL (FRONT AXLE)
AXLE BEARING AND SEAL INSTALLATION
INSTALLATION OF AXLE
AXLE SPROCKET REMOVAL & INSTALLATION
LOWER JACKSHAFT REMOVAL
LOWER JACKSHAFT SPROCKET REPAIR
LOWER JACKSHAFT INSTALLATION
DRIVE CHAIN ADJUSTMENT
BRAKE ASSEMBLY
ASSEMBLY OF BRAKE
BRAKE ADJUSTMENT

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
Hydraulic Circuit Operation
HYDRAULIC SYSTEM (600 Electric and 600 Diesel W/Petter Engine) (Hydraulic Flow)
Hydraulic System (600, 610 Gasoline and LP Gas) (Hydraulic Fluid Flow)
HYDRAULIC SYSTEM (600 and 610 Diesel W/Deutz Engine) (Hydraulic Flow)
RESTRICTOR FOR TILT HYDRAULIC CIRCUIT (Grapple Operation Only)
CHECKING THE CONDITION OF HYDRAULIC SYSTEM
RECOMMENDED HYDRAULIC OILFLOW RATE
CHECKING CONDITION OF HYDRAULIC PUMP
CHECKING THE PRESSURE SETTING OF THE CARTRIDGE RELEASE (In Lift and Auxiliary Control Valve)
MASTER RELEASE VALVE ADJUSTMENT
CARTRIDGE RELEASE ADJUSTMENT
CHECKING VARIABLE SPEED VALVE PRESSURE ADJUSTMENT (Variable Speed Swivel Couplings)
Variable Speed Control Valve With Holding Pressure Release Valve
CHECKING PRESSURE ADJUSTMENT (Variable Speed Control Valve with no Holding Pressure Valve )
VARIABLE SPEED CLOSING PRESSURE ADJUSTMENT (Variable Speed Control Valve with or with no Holding Release Valve)
VARIABLE SPEED HOLDING RELEASE PRESSURE SETTING (600 PSI [4137 kPa] Minimum)
DISASSEMBLY OF VARIABLE SPEED CONTROL VALVE (Seal Replacement with Control Valve in the Bobcat)
ASSEMBLY OF VARIABLE SPEED CONTROL VALVE, SEAL REPLACEMENT WITH CONTROL VALVE IN THE BOBCAT (With Holding Release Valve)
CONTROL VALVE SEAL INSTALLATION
INSTALLING VALVE SPOOL SEALS IN THE VARIABLE SPEED CONTROL VALVE
HYDRAULIC PUMP SERVICE (Webster Pump)
DISASSEMBLY
ASSEMBLY OF HYDRAULIC PUMP (Webster Pump)
HYDRAULIC PUMP DISASSEMBLY (Cessna Pump)
HYDRAULIC PUMP ASSEMBLY (Cessna Pump)
HYDRAULIC LIFT OR TILT CYLINDER DISASSEMBLY
INSTALLATION OF CYLINDER SEALS
HYDRAULIC CYLINDER ASSEMBLY
HYDRAULIC PUMP ALIGNMENT (500 ELECTRIC)
HYDRAULIC PUMP ALIGNMENT (600 Wisconsin)
37° Flare Connections
Tubelines and Hoses
Installing O–Rings

WISCONSIN ENGINE SERVICE
RETURN OF NORMAL COMPRESSION
GOVERNOR ADJUSTMENT
STORAGE OF ENGINE
RETURN STORED ENGINE TO SERVICE
CARBURETOR ADJUSTMENT
CARBURETOR RECONDITIONING
TO DISASSEMBLE THROTTLE BODY
DISASSEMBLY OF THE FUEL BOWL
O ASSEMBLE FUEL BOWL AND INTAKE ASSEMBLY
TO ASSEMBLE THROTTLE BODY
ASSEMBLY OF FUEL BOWL AND THROTTLE BODY
LP CARBURETOR SERVICE
CARBURETOR REMOVAL
LP CARBURETOR RECONDITIONING
DISASSEMBLY PROCEDURE LP CARBURETOR
CLEANING AND INSPECTION
ASSEMBLE LP CARBURETOR
VAPORIZER & PRIMARY REGULATOR SERVICE
DISASSEMBLING THE VAPORIZER
TO ASSEMBLE THE VAPORIZER
ADJUSTMENT OF VAPORIZER
LP FUEL FILTER LOCK–OFF
FUEL FILTER LOCK–OFF DISASSEMBLY
ENGINE RECONDITIONING
REMOVAL OF ENGINE
REMOVAL OF ACCESSORIES
REMOVAL OF FLYWHEEL
REMOVAL OF AIR HOUSING
REMOVAL OF CARBURETOR AND MANIFOLD
REMOVAL OF CYLINDER HEAD
REMOVAL OF GEAR COVER
REMOVAL OF CAMSHAFT
REMOVAL OF IDLER GEARAND SHAFT
REMOVAL OF OIL PAN
REMOVAL OF OIL PUMP
REMOVAL OF PISTONS AND CONNECTING RODS
REMOVAL OF VALVES AND SEAT INSERTS
REMOVAL OF CYLINDER BLOCK
REMOVAL OF CRANKSHAFT
REMOVAL OF CAMSHAFT
REMOVAL OF VALVE TAPPET
ASSEMBLY OF ENGINE AFTER RECONDITIONING INSTALLATION OF VALVE TAPPETS
INSTALLATION OF CAMSHAFT
INSTALLATION OF CRANKSHAFT
INSTALLATION OF VALVES AND SEAT INSERTS
INSTALLATION OF CYLINDER BLOCKS
INSTALLATION OF PISTON RINGS
INSTALLATION OF PISTONS AND CONNECTING RODS
INSTALLATION OF OIL PUMP
OIL PAN INSTALLATION
INSTALLATION OF IDLER GEAR AND SHAFT
INSTALLATION OF CAMSHAFT GEAR
INSTALLATION OF GEAR COVER
INSTALLATION OF CYLINDER HEAD
INSTALLATION OF CARBURETOR AND MANIFOLD ASSEMBLY
INSTALLATION OF AIR HOUSING
INSTALLATION OF FLYWHEEL
INSTALLATION OF ACCESSORIES

DEUTZ ENGINE SERVICE
INSTRUCTIONS FOR TIGHTENING BOLTS AND STUDS
CHECK AND ADJUSTMENTS
Adjustment of Valve Clearance
Compression Check
Checking Fuel System
Checking Fuel Injection Pump
To Find top Dead Center And Start Of Fuel Injection
Adjustment Of Start Of Fuel Injection
ENGINE RECONDITIONING
TO ASSEMBLE THE ENGINE
INSPECTION AND REPAIR
Checking The Crankshaft
Reconditioning Crankshaft
Checking Crankcase
Checking And Installing Main Bearing
Checking And Installing Camshaft And Bearings
Checking The Oil Pump
Installing A New Gear Starter Ring On Flywheel
Checking Front Cover And Repair Of Engine Governor
Check and Repair Of The Governor
Checking And Replacement Of Connecting Rod Bearings
Checking And Replacement Of Piston Pin Bushing
Checking Cylinders
Checking And Measuring Pistons
Repair Of Cylinder Head
Repair Of Rocker Arms
Repair Of Cooling Air Blower
Removing And Installing A Fuel Injection Nozzle
GENERAL ENGINE DATA (F2L410)
Torque Specifications (Deutz Engine)
FITS, CLEARANCES, ADJUSTMENTS – DEUTZ ENGINE
Oil System
Fuel System
Governor, Front Cover and Throttle
Cylinder Head and Valves
Cylinder and Piston
Camshaft, Crankshaft, Bearings
SPECIAL TOOLS
Mainframe & Hydraulics
Deutz Engine Tools

PETTER ENGINE SERVICE
ENGINE DISASSEMBLY AND REPAIR
Removal Of Connecting Rod
Removal Of Crankshaft
Removal Of Camshaft
Removal Of Oil Pump And Governor Assembly
Oil Filter
Lubricating Oil Pump
Installation Of Camshaft
Connecting Rod Assembly
Installation Of Cylinders And Pistons
Piston Assembly
Installation Of Cylinder Heads
Installation Of Valve Rocker Gear
Adjustment Of Valve Rockers
Adjustment Of Decompressor
Fuel Pump Installation
Fuel Filter Assembly
Fuel And Oil Filter Assembly
Timing The Engine
Injector Installation
TECHNICAL DATA (Fits, Clearances & Torques)

SPECIFICATIONS
ENGINE SPECIFICATIONS (WISCONSIN)
ENGINE SPECIFICATIONS (Wisconsin)
Fuel Specifications
Engine Oil
Specifications
Valve Mechanism
Crankshaft
Idler Gear
Connecting Rod
Piston, Piston Pin, Piston Rings
Ignition System
Distributor Advance Characteristics
Starter
Engine Torque Specifications
600 LOADER (WISCONSIN GAS)
OPERATIONAL & PERFORMANCE
ENGINE
LOADER HYDRAULICS
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
COUNTERWEIGHT
MACHINE WEIGHT (Less Bucket)
610 LOADER (WISCONSIN GAS)
OPERATIONAL & PERFORMANCE
ENGINE
LOADER HYDRAULICS
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
COUNTERWEIGHT
MACHINE WEIGHT (Less Attachments)
ENGINE SPECIFICATIONS (DEUTZ)
ENGINE SPECIFICATIONS (Deutz F2L 411)
Fuel System
Lubrication System
overn, Front Cover and Throttle
Cylinder Head and Valves
Cylinder, Piston and Connecting Rod
Camshaft, Crankshaft, Bearings
Torque Specifications
Special Tools
600D LOADER (DEUTZ DIESEL)
OPERATIONAL & PERFORMANCE
ENGINE
LOADER HYDRAULICS
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
COUNTERWEIGHT
MACHINE WEIGHT (Less Bucket)
611 LOADER (DEUTZ DIESEL)
OPERATIONAL & PERFORMANCE
ENGINE
LOADER HYDRAULICS
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
COUNTERWEIGHT
MACHINE WEIGHT (Less Bucket)
611D LOADER (BUREAU OF MINES APPROVED)
OPERATIONAL & PERFORMANCE
ENGINE
LOADER HYDRAULICS
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
COUNTERWEIGHT
MACHINE WEIGHT (Less Attachments)
ENGINE SPECIFICATIONS (PETTER)
ENGINE SPECIFICATIONS (Petter)
Fuel Specifications
Engine Oil
Specifications
Lubrication System
Cylinder Head
Valve Mechanism
Camshaft
Crankshaft
Crankshaft Regrinding Diameters
Connecting Rod
Piston
Cylinder Block
Torque Specifications
600D LOADER (DEUTZ DIESEL)
OPERATIONAL & PERFORMANCE
ENGINE
LOADER HYDRAULICS
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
COUNTERWEIGHT
MACHINE WEIGHT (Less Bucket)
MOTOR SPECIFICATIONS, (ELECTRIC)
600E LOADER (RELIANCE ELECTRIC)
OPERATIONAL & PERFORMANCE
MOTOR
LOADER HYDRAULICS
POWER TRAIN
CAPACITIES
TIRES
COUNTERWEIGHT
MACHINE WEIGHT (Less Attachment)
TECHNICAL DATA
LOADER TORQUE SPECIFICATIONS
Hydraulic Fluid
Special Tools
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION
STANDARD TORQUE SPECIFICATIONS FOR BOLTS

ALPHABETICAL INDEX

SERVICE BULLETINS
019
042

SERVICE MANUAL REVISIONS
600-002
600-003

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