SM-Bobcat 630, 631, 632 Skid Steer Loader Service Repair Manual PDF

2 of 284
Dealer Copy -- Not for Resale

MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING 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
instructions can cause injury or death. W-2003-0903
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 Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG

B-11799 B-15231 B-15280
Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-6590 B-6580 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
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
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FOREWORD PREVENTIVE
MAINTENANCE
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 HYDRAULIC
Checks, Bucket Operation, Minor Maintenance, etc.).
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.
4. Check battery condition and cables. DRIVE

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

MAIN
7. Check indicator lamps. FRAME

8. Check tires for wear and pressure.
9. Check the Bob–Tach attachment for condition. Inspect the wedges for damage or wear.
ELECTRICAL
10. Inspect safety items for condition (Operator Guard, Seat Belt, Safety Treads, Lamps, etc.). SYSTEM
11. Make a visual inspection for loose or broken parts or connections.
12. Operate the loader, checking all functions.

ENGINE
Advise the owner if any of the above items are in need of repair. SERVICE
CONTENTS TECHNICAL
DATA
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ALPHABETICAL
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 INDEX
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
630, 631, 632 Loader

5 of 284 –1––3– Service Manual
630, 631, 632 Loader

PREVENTIVE MAINTENANCE
PREVENTIVE
Paragraph Page MAINTENANCE
Number Number
BOB–TACH AND PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . 1–8 1–16
ENGINE MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 1–17
ENGINE SERVICE (GENERAL) . . . . . . . . . . . . . . . . . . . . . . 1–3 1–4
HYDRAULIC FLUID AND FILTER . . . . . . . . . . . . . . . . . . . . 1–4 1–14
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 1–1
LOADER LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 1–16
SERVICE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 1–3
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 1–15
TRANSMISSION & DRIVE SYSTEM . . . . . . . . . . . . . . . . . . 1–5 1–15
630, 631, 632 Loader

630, 631, 632 Loader

8 of 284 –1–0– Service Manual
1 PREVENTIVE MAINTENANCE
Engine Serial
1–1 INTRODUCTION Number
1–1.1 Symbols
IMPORTANT
This notice identifies
procedures which must be
B–02674R
followed to avoid damage to
the machine. 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 Fig. 1–3 Engine Serial Number (631)
is on the inside of the lift upright, above
the grill (Fig. 1–1). Explanation of serial
number:
XXXX M XXXX
Production Sequence (Series) Engine Serial
Plant Location Number
Model, Engine Version
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 Engine Serial Number (632)
630, 631, 632 Loader

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 Fig. 1–5 Pre–Delivery Inspection
MELROE DIVISION
QUALITY CONTROL DEPT.
GWINNER, NORTH DAKOTA 58040
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. Fig. 1–6 30 Hour Inspection
1–6) must be completed by the
dealer’s mechanic, according to
specification in this manual.
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.
630, 631, 632 Loader

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*
SERVICE SCHEDULE HOURS
8–10
1000
250
300
500
100
50
630
631
632
ITEM SERVICE REQUIRED

Engine Air Cleaner Clean dust cup. Inspect condition of system.
Engine Oil Check and add oil as necessary.
Engine Cooling System Check coolant lever. Add coolant when low. Remove any debris from
radiator grill area.
Engine Coolinf Inlet Check rear door grill and blower inlets for restriction of air flow. Clean
cylinder cooling fins and blower housing, when necessary.
Tires Inspect for damage and check air pressure in tires.
All Pivot Points Add lubricant to all fittings (12).
Indicators, etc. Check for correct operation of all inficatos, switches, lights.
Operator Guard Check condition of guard and bolts.
Seat Belt Check condition of straps and buckle and make replacement if there is a
defect.

Safety Decals Be sure all decals are in place and can be read. Make replacement as
necessary.
Hydraulic Fluid Check level and add recommended fluid if necessary.
Engine Oil & Filter Make replacement of oil and filter.
Crankcase Breather Clean breather cap every oil change.
Battery Check water level. Add water if necessary.
Control Pedals & Steering Check operation. Make repairs and adjustments as necessary.
Bob–Tach Inspect locking levers and wedges for condition and operation.
Brakes Check operation. Make adjustment as necessary.
Distributor Cam (Wisconsin) Put 3 – 5 frops of oil in spring cap oil cup.
Spark Arrestor Muffler Remove plug. Run engine to remove carbon.
Chaincase Fluid Check level. Add fluid if necessary.
Hydraulic Filter Make replace of filter element.
Engine Cylinder Head Bolts Tighten to correct torque after first 100 hours. Also make adjustment to
valves if necessary.
Engine Air Cleaner Inspect system for leaks. Replace element, if necessary.
Crankcase Breather Remove and clean breather assembly.
Valve Tappets Check clearance. Make adjustment when required.
Starting Motor Remove, clean and serice as required.
Engine Fuel Filter Replace element or clean as necessary.
Main Fuel Filter Make replacement of element (Vent air from system after chainging
element.)
Engine Compression The minimum compression reading must be at least 75% of maximum
compression reading.
Chaincase Make replacement of fluid.
Hydraulic System Make replacement of fluid and filter. Clean cap and vent.
630, 631, 632 Loader

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).
1/2’’ 1.11–1.17
WARNING
Door must be closed when 5.83
operating the loader. 5.89
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.
B–02196 A–02506
A door stop can be installed to prevent Fig. 1–7 Releasing Rear Door Fig. 1–8 Hole Location
the door hinge from coming out of the
hole.
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
3. Install the bolt and nut and tighten to 40–50 ft.–lbs. (54,2–67,8 Nm) torque. Stop
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
630, 631, 632 Loader

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 Dipstick
Oil Drain Cap C–02299

Fig. 1–12 Engine Servicing (631)
630, 631, 632 Loader

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 Minimum
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 Maximum B–02663

(GASOLINE: USE API CLASSIFICATION SE) Fig. 1–13 Checking Crankcase Oil (632)
(DIESEL: USE API CLASSIFICATION CD)
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.
Replacement Oil and Filter: Oil Filter
1. Stop the engine. Crankcase

Drain
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 Filter Location (630)
630, 631, 632 Loader

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. A–01601
Fig. 1–16 Crankcase Breather (631)
1–3.3 Air Cleaner System
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:
B–02677
1. Remove and clean dust cup every day (Fig. 1–18). 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 Condition
new element and (2) be sure Indicator

gasket is in correct place.
3. Inspect complete air cleaner Gasket

system and make replacement of Element
any parts with defects. Be sure Rubber Dust
hose connections are tight. Baffle Cup
4. 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). Clamp
Check the condition indicator for
the red ring (631); if the red ring C–01024R
appears, the system is good. 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
630, 631, 632 Loader

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

adding fuel. NO SMOKING! Failure to
WARNING 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 Adapter
the parts as shown in figure 1–21 (See Parts catalog for the Parts). (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). Fuel

Filter Fuel
‘‘Shut–Off’’
2. Loosen hose clamp and remove hose from outlet end of fuel filter. (Gasoline
Model) Valve
3. Connect a short piece of hose to the outlet end of fuel filter and turn fuel valve B–02191
on. Fig. 1–21 Fuel Filter and Valve
630, 631, 632 Loader

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 Adjustment (Fig. Throttle

1–22). Stop Screw
Idle Adjustment
Adjust the idle screw for the best low Needle
speed operation.
The engine must idle at 1125 to 1150
RPM.
Repair kits are available for this
carburetor.
C–02319R
Fig. 1–22 Carburetor Adjustment (630)
630, 631, 632 Loader
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
3. If engine does not run smoothly, Adjustment
turn needle out until it does.
B–02409
Throttle Idle Adjustment
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.

1–3.4b Fuel Shut–Off Cap
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. B–02672R
Fig. 1–24 Coolant Recover Tank
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.
1/2’’ (13 mm)
C–02299
Fig. 1–25 Belt Tension Adjustment (631)
630, 631, 632 Loader

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 temperature sender B–02661

switch.
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.
630, 631, 632 Loader

Front Lights

Light Switch
Fuse
Transmission
Warning
Hourmeter Light
Rear Light
Engine Warning
Voltmeter Light
Kwy Switch
E–01299
Fig. 1–27 ROPS Electrical System
630, 631, 632 Loader

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.
You must wear goggles when you

work near batteries. Do not let acid
WARNING 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

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.
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.
• Battery cables are connected when
IMPORTANT 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
630, 631, 632 Loader

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.
B–02946
3. Loosen adjustment screw. Move breaker arm contact until correct gap is Fig. 1–29 Battery Hold Down
given. Tighten screws again.
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 Check
upper valve clockwise until tight. Valve
Use only SAE 10W–30 or 10W–40 oil which has an API classification of SE.
DO NOT USE AUTOMATIC Lower Check

IMPORTANT TRANSMISSION FLUID IN THE
HYDRAULIC/HYDROSTATIC
Valve
B–02673
SYSTEM. I–2154–1297
Fig. 1–30 Checking Hydraulic Fluid
630, 631, 632 Loader

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)

1/4’’ Spacer
1. Put brake pedal in open position. Adjustment
Nut
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 C–02366
100 hours.
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 Plug
is 45–50 PSI (310–340 kPa).
C–02037
Fig. 1–33 Chaincase Check/Fill Plug
630, 631, 632 Loader

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).
Check lockbolt nuts to be sure all are tight. Grease
NOTE: Some Bob–Tach’s will not fit into the mounting frame of B–02135
attachments (Example: Pallet Fork, Angle Broom, etc.). Grind away Fig. 1–36 Seat Rail Lubrication
1/4’’ (6,35 mm) of material from each side of the Bob–Tach (Fig.
1–38).
Remove Material Here
B–02246 D–01380
Fig. 1–37 Pivot Pin Lockbolts Fig. 1–38 Bob–Tach
630, 631, 632 Loader

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 Engine Muffler Installation
630, 631, 632 Loader

630, 631, 632 Loader

HYDRAULIC SYSTEM
Paragraph Page
Number Number
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 2–9
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 2–7
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6 2–12 HYDRAULIC
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5 2–12 SYSTEM
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . 2–2 2–7
HYDRAULIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 2–3 2–8
QUICK COUPLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 2–18
630, 631, 632 Loader

630, 631, 632 Loader

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2 HYDRAULIC SYSTEM
2–1 HYDRAULIC CIRCUIT (See Pages 2–1 Thru 2–6)
1. The hydraulic fluid moves from the reservoir to the port block and the system Mark a Line on Nut
hydraulic pump and to the control valve. Flats of Both Nuts
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 Tighten to Correct
the passage of fluid through the hydrostatic system. 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
When repairing hydrostatic and

hydraulic systems, clean the work
area before disassembly and keep all
IMPORTANT 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.
Tube Size Rotate No.

Wrench Size Outside Dia. Thread Size of Hex Flats
O–ring
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 A–01852
Fig. 2–2 Straight Thread Seal
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
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. A–01852
2–2). Put oil on the O–ring. Fig. 2–3 Seal In Place
630, 631, 632 Loader
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 A Check control linkage and fluid
hydraulic power on all circuits. level. Check release pressure
and pump output. Check for
damage to tubelines.
O–ring
Slow hydraulic action or no B Check control linkage, cylinder
hydraulic on one circuit. condition. Check valve section
for leakage. Check for damage
to tubelines. A–01897
Fig. 2–4 Wrong Installation
Cylinders move the controls in B Check cylinder condition.
neutral position (See NOTE Check valve section for
Below). leakage. Check for tubeline
leakage.
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 Control
Check Linkage Check Release Check Output
Fluid If Adjustment If Pressure If Of Vane Pump
Level Full & Free Good (Sec. 2–5) Good (Sec. 2–6)
Movement
If If Not If Not If Not

Low Correct Correct Correct
Make Remove, Clean

& Inspect Make Repairs
Add Corrections As Needed
Fluid As Needed Relief Valve
(Sec. 2–5.1) (Sec. 2–7)
CHART B
SLOW HYDRAULIC OR NO HYDRAULIC POWER TO ONE CIRCUIT
ONLY, CYLINDERS MOVE WITH CONTROLS IN NEUTRAL POSITION.
Check Control Check Condition Remove, Clean &

Linkage Adjustment If Of Cylinders If Inspect Control
& Free Movement Correct (Sec. 2–8.1) Good Valve (Sec. 2–10)
If Not If If
Correct Bad Bad
Make Repair Make Repairs Make Repair

Or Adjustment Or Replacement Or Replacement
As Needed As Needed (Sec. 2–9) As Needed
630, 631, 632 Loader

2–4 CONTROL VALVE Relief Valve
Tilt Orifice
Wear in the control valve or spools will S/N 11463 & Above
cause the hydraulic cylinders to move (.086’’)
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 Lift Detent Assembly
inside the cylinders. (See
HYDRAULIC CYLINDERS).
2–4.1 Removing Control Valve O–ring
1. Remove seat and transmission Load Check

cover. Valve Auxiliary Detent Assembly
2. Disconnect control linkages, Lift Orifice
tubelines and hoses from control (.125’’) D–01385R
valve.
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 Detent

bolt 6–8 ft.–lbs. (8–11 Nm) torque. Position Is All
The Way In
D–01385R B–02821
Fig. 2–6 Control Valve Fig. 2–7 Load Check Valves
630, 631, 632 Loader
6. Install lift and auxiliary spools the
same way and put a screwdriver Detent
through the hole in tilt spool to Caps
keep other spools from moving
when installing detent caps (Fig.
2–8).
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 B–02824
1. Put linkage end of spool in vice. Fig. 2–8 Installing Detent Caps 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.
Put jackstands under the front axles

and rear corners of the frame before
running the engine for service.
WARNING 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. B–02797
3. Connect a tester or pressure gauge to auxiliary lines as shown (Fig. 2–10). Fig. 2–10 Checking Release Pressure
Tester can also be connected to tilt cylinder hoses.
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
630, 631, 632 Loader

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)

%= x 100
FREE FLOW (GPM)
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.
630, 631, 632 Loader

2–5 HYDRAULIC PUMP
2–5.1 Checking Output of Pump
From The
Hydraulic
1. Operate Bobcat for a few minutes Control Valve From The
until the oil is warm, before Tester Outlet
checking put output.
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
W–2017–0286
3. Remove wheels and seat

assembly.

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 From The
relief valve in the system. 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
2–6.1 Checking Lift Cylinders Bolts
1. Stop the engine and activate controls to release hydraulic pressure. B–02799
Fig. 2–13 Hydraulic Pump Replacement
630, 631, 632 Loader

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
2–6.2 Checking Tilt Cylinder Base End Of Lift Cylinder
B–02795
1. Stop the engine and activate controls to release hydraulic pressure. 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
1. Stop the engine. Base End Of Lift Cylinder
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 Checking Tilt Cylinder
630, 631, 632 Loader

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 the oil from the

B–03663 B–03087
cylinder.
Fig. 2–17 Removing The End Cap 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 B–03670
8. Remove the piston (Fig. 2–21). Fig. 2–19 Removing End Cap & Piston 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 B–03693
Fig. 2–21 Removing The Piston Fig. 2–22 Removing O–ring
B–03685 B–03670
Fig. 2–23 Removing The End Cap Fig. 2–24 Removing O–ring
630, 631, 632 Loader

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 B–03674
Fig. 2–25 Removing Wiper Seal 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 B–03703
16. Make inspection of parts for Fig. 2–27 Removing Teflon Seal Fig. 2–28 Removing The O–ring
scratches, nicks, bent, etc.,
replace as needed.
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. B–03674 B–03675
Fig. 2–29 Installing Piston On Tool Fig. 2–30 Installing O–ring
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–03677 B–03673
Fig. 2–31 Installing Teflon Seal Fig. 2–32 Installing Piston Into Tool
630, 631, 632 Loader
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).
B–03672 B–03671
24. Install the back–up washer Fig. 2–33 Install Oil Seal On Tool Fig. 2–34 Installing Oil Seal
(Fig. 2–36).
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 B–03679
Fig. 2–35 Installing Wiper Seal Fig. 2–36 Installing Back–Up Washer
B–03681 B–03685
Fig. 2–37 Installing O–ring Fig. 2–38 Installing End Cap
B–03693 B–03692
Fig. 2–39 Installing O–ring Fig. 2–40 Installing The Piston
630, 631, 632 Loader

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 B–03670 B–03675
Fig. 2–45) (small cylinder Fig.
2–46). Fig. 2–41 Tightening Nut Fig. 2–42 Putting Oil On Seals

B–03691 B–03665
Fig. 2–43 Putting Oil On Seals Fig. 2–44 Installing Assembly
B–03663 B–04682
Fig. 2–45 Tightening End Cap Fig. 2–46 Tightening End Cap
630, 631, 632 Loader

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

2–3/4 in.
2–7.1 Restriction in the Quick (69,85 mm)
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. 1/8 in. 1–1/2 in. A–02644
(3,175 mm) (38,1 mm) C–02001
The adapter on the male quick Fig. 2–47 Installing Spacer In Tilt Cylinder
coupler has a ‘‘taper’’ end which can
cause the restriction in the hydraulic
oil flow and over–hearting. Remove Quick Coupler
the quick coupler (Fig. 2–48) and the
Adapter
adapter and cut away the ‘‘taper’’
about 3/16’’ (4,76 mm) (Fig. 2–49).
Do not cut the threads on the 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
630, 631, 632 Loader

HYDROSTATIC SYSTEM
Paragraph Page
Number Number
BY–PASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5 3–18
HYDROSTATIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 3–13
HYDROSTATIC MOTORS
(630 & 632 S/N 15320 & Below) . . . . . . . . . . . . . . . . . . . . 3–8 3–26
HYDROSTATIC MOTOR REPAIR
(630 & 632 S/N 15320 & Below) . . . . . . . . . . . . . . . . . . . . 3–9 3–30
HYDROSTATIC MOTOR REPAIR
(631 & 632 S/N 15321 & Above) . . . . . . . . . . . . . . . . . . . . 3–10 3–36 HYDROSTATIC
HYDROSTATIC PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . 3–7 3–19 SYSTEM
HYDROSTATIC TROUBLESHOOTING . . . . . . . . . . . . . . . 3–2 3–13
PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6 3–18
REPLENISHING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4 3–17
STEERING CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11 3–41
STEERING LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . . 3–3 3–16
630, 631, 632 Loader

630, 631, 632 Loader

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 None Check for hydraulic leaks.

direction. Check steering linkage,
check replenishing valve
(Sec. 3–4.1).
No drive, one side, both B Check linkage. Check for
directions. pump or motor damage.
Machine does not move in a C Check dia. and size of tires
straight line. 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.
630, 631, 632 Loader

CHART A
NO DRIVE ON EITHER SIDE
Check If Turn Ignition If ‘‘Trans’’ Start Engine &

Fluid Level Correct Switch ‘‘ON’’ Light Run At 1/2 Throttle
Comes On
If Light Does
If Low Not Come On If Light Is On
Make Repair Make Repairs Make Repair

Or Adjustment Or Replacement Or Replacement
As Needed As Needed (Sec. 2–9) As Needed
If Light Is On
Remove, Clean &

Check

Inspect By–Pass
Vane Pump Valve (Sec. 3–5)
If Light Goes Out
If Good
If Light Is On
Hydrostatic Pump
Make Repairs Has Defect. Remove,
Check Clean & Inspect
To Controls Pump Drive Pump And Motor
(Sec. 3–6 & 3–8)
CHART B
NO DRIVE: 1 SIDE, BOTH DIRECTIONS
Check Start Engine & If Light

If Turn Ignition If Is Off Hydrostatic Motor
Steering Light Run At 1/2
Linkage Good Switch ‘‘On’’ But No Has Defect
Is On Throttle
Drive
If Not If Light If Light

Correct Is Not On Stays On
NOTE: If Either
Make Repairs Hydrostatic The Pump or Motor
As Needed Repair Electrical Pump Has Damage,
(Sec. 3–10) System Has A Defect Remove, Clean &
Inspect
Both Units.
630, 631, 632 Loader

CHART C
BOBCAT DOES NOT MOVE IN A STRAIGHT LINE
Check Size Check Steering Go To

& Pressure If Linakge If
Correct Correct Chart B
Of Tires (Sec. 3–10)
If Not Correct If Not Correct
Change Tire Make Repairs

Or Pressure As Needed
As Needed

CHART D
BOBCAT OVERHEATS
Check If Hydraulic
Check Controls Are
Fluid Level If Check & Clean If If Check
Oil Cleaner Being ‘‘Temp Sender’’
Correct Clean Held Out Of Not
(Sec. 1–11)
Neutral Position
If Low If So
Loader Is
Not Being
Add Fluid Operated
Correctly
630, 631, 632 Loader

3–3 STEERING LINKAGE
ADJUSTMENT (Fig. 3–1 & 3–2) TO THE FRONT
Adjust Bar Tight OF THE BOBCAT
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 Centering
backward causing injury or Spring
death. Centering Bar
W–2014–0895
Pintle Pintle 630 (S/N 15300 & Below)
Lever Bar 631 (S/N 12253 & Below)
1. Remove seat and steering 632 (S/N 15450 & Below) C–02375
shields.
Fig. 3–1 Steering Adjustment
NOTE: On the 630 (S/N 11512 &
Below); 631 (S/N 1114 &
Below); and 632 (S/N
12006 & Below), there are Pintle
new pintle levers available Lever
if the old style breaks. To Cam Adjust Cam Tight TO THE FRONT

install the new pintle Against Both Lobes OF THE BOBCAT
levers. (See BTI Bulletin
#130.
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). Centering
Adjust rear pintle bar so that the Centering Bar Spring
bar is tight against both lobes of
pintle lever and the Pintle 630 (S/N 15301 & Above)
transmission is still in neutral. Bar 631 (S/N 12254 & Above)
Tighten bottom bolt first to 28 632 (S/N 15451 & Above) C–02544
ft.–lbs. (38 Nm) torque, then
tighten top bolt to 28 ft.–lbs. (38 Fig. 3–2 Steering Adjustment
Nm) torque.
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.
630, 631, 632 Loader

10. Install new locknuts on these CHARGE FLUID
bolts and tighten to 23 ft.–lbs.
(31 Nm) torque.
11. Install seat and seat plate.
12. Remove jackstand and lower lift
arms.
3–4 REPLENISHING VALVE (Figs. FUNCTION 1
3–3 & 3–4)
Valve Moves For Charge
The replenishing valves for forward Fluid Replacement
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 FUNCTION 2
valves are: Valve Stays On Seat To
Hold High Pressure For Drive
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).
FUNCTION 3
2. Keep high pressure fluid flow Valve Release Very High
out of low pressure side of Pressure To Protect System B–02805
closed hydrostatic circuit (Fig. Fig. 3–3 Replenishing Valve – Forward
3–3, Function 2 & Fig. 3–4,
Function 2).
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). CHARGE FLUID
3–4.1 Checking Replenishing
Valves
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
2. Make exchange of vales and Fluid Replacement
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.
FUNCTION 2
4. Put coloring fluid on the valves
and let dry. Valve Stays On Seat To
5. Use a small pliers to install Hold High Pressure For Drive
valves into hole. Push the
valves against the seat and turn B–02804
it very little. Fig. 3–4 Replenishing Valves – Reverse
630, 631, 632 Loader

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 1
conditions, which can cause over–heating of the hydrostatic
system.
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.
When making repairs on hydraulic

system, clean the work area before
disassemble and keep all parts clean.
IMPORTANT Always use caps and plugs on
hoses, tubelines and ports to keep
Bronze
Element
dirt out. Dirt can quickly damage the
system.
I–2056–0793 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.
630, 631, 632 Loader

3–7 HYDROSTATIC PUMP ASSEMBLY – REPAIR Shoes Turn This Direction
On Wafer Plate
Keep all hydrostatic parts CLEAN!
Dirt in the system will cause damage
IMPORTANT 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 Wafer Plate
assembly.
Alignment Pin B–02816
3–7.1 Hydrostatic Pump Disassembly
Fig. 3–7 Wafer Plate
1. Put mark across all sections of hydrostatic pump assembly so that pump is
reassembled in the correct way.
2. Remove two bolts that hold vane pump to hydrostatic pumps. Gasket
3. Remove O–ring, snap ring, collar with spline and vane pump drive shaft. Bearing
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. B–02817
6. Remove gasket, bearing and bearing spacer (Fig. 3–8). Fig. 3–8 Bearing Spacer & Gasket
Keep all the parts for one pump

IMPORTANT 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.
Be sure not to damage shims under

pintle covers. If shims are damaged,
shims need repacement with shims
IMPORTANT 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.
630, 631, 632 Loader

13. Use a press to remove bearing
from drive shaft and bearing This Dimension Must be Maintained on All
race from housing. Use step 4 Nine Shoes Within 0.001 Inch
thru 12 for disassembly of the
other pump unit.
Piston
IMPORTANT Shoe
Keep parts for each pump

separate. Some parts will fit
both pumps but must not be Shoe Must Swivel
used in the other pump Smoothly on Ball
because of specific wear End Play Must Not
patterns. Shoe Faces Sides Exceed 0.05 Inch
I–2165–0398 On Swash Plate
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
W–2317–0598 A–01870
Fig. 3–10 Cylinder Block
630, 631, 632 Loader

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,
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,
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.
630, 631, 632 Loader

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 measured distance
between spacer and
housing face. C–02272
plus .027 measured distance at
180 from first Fig. 3–11 Checking Pre–Load Assembly
measurement.
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
630, 631, 632 Loader

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 Small End Of Bearing
to give correct compression of o–ring and prevent leakage at the Toward Manifold Block
seal.
f. Install pintle cover/seal on long pintle shaft.

g. Install four pintle cover screws. If the screws have separate lock washers,
Nm) torque.
Use the same procedure to install yoke and bearings in other pump. Chamfer
Toward
Pump B–02817
NOTE: The yoke must move with slight resistance, but must not move hard Fig. 3–13 Bearing & Spacer
or with no resistance.
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
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
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)
.150 measured thickness of thickest bearing spacer
minus .027 average gap (from f. above)
plus .003 ± .001 necessary preload
plus .020 compressed thickness of gasket
equals .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).
630, 631, 632 Loader

3. Install pin retainer about 1/4 inch. (6,35 mm) below surface with opening Three Pins
away from large splines ( Fig. 3–15).
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 A–02501
intermediate shaft, with chamfer toward shoulder on shaft. Fig. 3–15 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)

.150 measured thickness of thickest bearing spacer
minus .027 average gap (from e. above)
plus .002 ± .001 necessary preload
plus .020 compressed thickness of gasket
equals .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.
630, 631, 632 Loader

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.
Be sure to use the correct wafer plate.

IMPORTANT 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)
Always keep hydraulic and

hydrostatic parts clean. Clean
outside of all assemblies before
IMPORTANT beginning repairs. Use plugs and
caps to cover open ports. Dirt can
quickly damage the system.
I–2173–0598
630, 631, 632 Loader

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.

and rear corners of frame before
W–2017–0286
3. Remove the ROPS:

a. Remove holddown nuts and bolts; remove rear top grill.
C–02361R
b. Remove backhoe mounting brackets, if installed. Fig. 3–16 Removing Steering Linkage
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 1–1/2’’ B–03019R
block under one (1) pump Fig. 3–17 Remove Charge Inlet Hose
mount (Fig. 3–17). This will give
more spacer for cover removal.
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 B–03021
Fig. 3–19 Remove Caliper Assy & Covers Fig. 3–20 Remove Disc Brake
630, 631, 632 Loader

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
19. Install plugs in the motor and pump openings. Fig. 3–21 Remove Motor Mount Bolts
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.
B–03020
2. Install the motor with two (2) large openings facing toward the rear. Fig. 3–22 Remove Motor
3. Put the rear chain over the motor sprocket (Fig. 3–22).
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 B–03023
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)). Fig. 3–23 Install Front Drive Chains
9. Repeat this procedure for both

motors. 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 C–02364 B–03022
washer (Fig. 3–25). Fig. 3–24 Peening Connector Links Fig. 3–25 Disc Brake Installed
630, 631, 632 Loader
Making The Special Tool For Holding Motor Sprockets (Fig. 3 - 26)
a. Use an old brake disc.

2’’ 1–3/4’’
b. Cut a piece of metal material approximately 9–1/2’’ long by 1–3/4” wide
by 3/8’’, for a handle.
c. Weld the handle to the brake disc.
d. Put the handle so that 2’’ of metal handle is welded to the brake disc. 3/8’’
9–1/2’’
12. Put the special tool on the sprocket.
13. Use the special tool (6559556) for torque wrench to tighten sprocket
B–03027
retaining nuts to 300 ft.–lbs. (407 Nm) (Fig. 3–27). Keep the wrench straight
in line with handle of special wrench. 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 Set Torque To

12’’ 150 - 175 ft.–lbs.
18’’ 180 - 210 ft.–lbs.
24’’ 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. Fig. 3–27 Tighten Sprocket Nuts
3–21).
16. Install the case drain hoses.
17. Tighten the lock nuts on the case drain elbows.

Long Short
18. Clean the four (4) high pressure hoses in solvent. Hose Hose
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 B–03031
side.
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.
630, 631, 632 Loader

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.
DO NOT move the steering levers to

full forward or backward position.
IMPORTANT This will cause damage to the
motors.
I–2174–0598
630, 631, 632 Loader

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).
OPEN CENTER SYSTEM CLOSED CENTER SYSTEM
• Larger shaft bearings. MOTOR MOTOR
• Larger thrust bearings. B–03389
Fig. 3–29 Motor Identification
• A heavier housing.
Later motors do not have a dust seal.
Service parts are available as
follows:

• 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 Open Center
information.
Before you install a new motor, you Closed Center
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 B–03387
system) or if there is a plug installed
in the housing (closed center system) Fig. 3–30 Open And Closed Spools
(Fig. 3–29).
B–03385 C–02362
Fig. 3–31 Removing Sprocket
630, 631, 632 Loader

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
End Cap
NOTE: Make sure you check the
end play of the shaft
B–02876
before disassembly (See
Section 8 For Fig. 3–32 Remove End Cap
Specifications).
1. Remove sprocket from motor
shaft by removing nut and using S/N 12999 & Below
a puller or a hydraulic press
(Fig. 3–31).

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

C–02388
Fig. 3–33 Hydrostatic Motor Breakdown
630, 631, 632 Loader

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 B–02841 B–02877
(Fig. 3–38).
*Fig. 3–34 Removing Drive Shaft 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 B–02842 B–02872
of tool with numbered side
toward chamfer (Fig. 3–39). Fig. 3–36 Removing Snap Ring & Seal Fig. 3–37 Removing Needle Bearings
(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). *
*
* *
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
630, 631, 632 Loader

5. Remove installation sleeve and
collar. Wiper Seal
Snap Ring
6. Install shim on seal, then install Spacer
spacer and snap ring (Fig. Installation
3–30). Be sure the snap ring is Sleeve
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 Installation
the area between seal and Collar
Rubber Sealing B–02874
the spacer.
Ring Fig. 3–40 Thrust Bearing
7. Install wiper seal (Fig. 3–39).
8. Install thrust bearings and

washers (Fig. 3–40). The thrust A–02522
washers must have the Thrust
Fig. 3–39 Motor Seal Identification Washer Chamfer Bearing
chamfers facing away from the
bearing (Fig. 3–41).
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 Thrust
inches (3,81–5,334 mm). Bearing Washer
Chamfer
A–02679
11. Put housing in a vise. Put tape over key slot on shaft to prevent seal damage.
Install shaft in housing. 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 B–02857
Fig. 3–43 Checking Bearing Location Fig. 3–44 Ball & Pin (S/N 12999 & Below)
630, 631, 632 Loader
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
13. Install drive link in coupling shaft Close Alignment
(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 B–02895R
15. Install wear plate over shaft (Fig. Fig. 3–45 Housing Seal Ring *Fig. 3–46 Installing Drive Link
3–48).
16. Install stator ring and rotor

assembly (Fig. 3–49).
17. Install manifold plate (Fig.

3–50).
B–02865 B–02863
Fig. 3–47 Thrust Bearing Installation Fig. 3–48 Wear Plates
B–02864 B–02866
Fig. 3–49 Installing Stator Ring & Rotor Fig. 3–50 Manifold Plate Installation
630, 631, 632 Loader

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 B–02867R
Fig. 3–51 ManifoldInstallation 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 B–02870R

reservoir and add oil as needed. *Fig. 3–53 Commutator Rind Installation
B–02891
Fig. 3–54 Installing Protector Sleeve
630, 631, 632 Loader
3–10 HYDROSTATIC MOTOR
REPAIR (630 - S/N 15376 & Above,
631 and 632 - S/N 15321 & Above)
3–10.1 Disassembly of the
Hydrostatic Motor
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 B–05117 B–05118
the shaft in the down position.
Put a mark across the motor Fig. 3–55 Marking Motor Sections Fig. 3–56 Removing Motor Bolts
sections for correct assembly
(Fig. 3–55).
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 B–05120 B–05126

(small and large) (Fig. 3–58) Fig. 3–57 Removing Valve Housing Fig. 3–58 Removing O–rings
from the valve housing.
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).
B–05127 B–05128
9. Remove the two (2) springs
from the balance plate (Fig. Fig. 3–59 Removing Plug Fig. 3–60 Removing Springs
3–62).
B–05129 B–05124
Fig. 3–61 Remving Shuttle Valve Fig. 3–62 Removing Spring From Plate
630, 631, 632 Loader

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). B–05130 B–05134

Make sure the rollers are kept in Fig. 3–63 Balance Plate Seals Fig. 3–64 Removing The Valve
the geroler.
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
B–05123 B–05122
19. Turn the bearing housing over in Fig. 3–65 Removing Valve Plate Fig. 3–66 Removing Valve Drive
the vise and remove the eight
bolts (Fig. 3–70).
20. Using a plastic hammer, tap the

mounting flange from the
housing.
B–05121 B–05119
Fig. 3–67 Removing The Geroler Fig. 3–68 Removing Drive Shaft
B–05125 B–05132
Fig. 3–69 Removing The O–rings Fig. 3–70 Removing The Bolts
630, 631, 632 Loader
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).
B–05141 B–05142
22. Remove the dust seal and inner
seal from the mounting flange Fig. 3–71 Removing Back–Up Washer Fig. 3–72 Removing Seal
(Fig. 3–73 & 3–74).
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 B–06768
Fig. 3–73 Removing Dust Seal Fig. 3–74 Removing Inner Seal
Model 109–1052–005 & Below Shaft Face Seal
3–1/2’’ O–ring 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
630, 631, 632 Loader

3–10.2 Hydrostatic Motor
Inspection
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.
d. Check the valve plate (Fig. B–05140
3–80). Fig. 3–77 Removing Shaft Seal
e. Check the valve (Fig. 3–81 &
3–82).
f. Check the balance plate (Fig. B–05135
3–83). 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 B–04643
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 Fig. 3–78 Checking Geroler
of the parts.
B–04631 B–04634
Fig. 3–79 Checking Rollers Fig. 3–80 Checking Valve Plate
B–04638 B–04626
Fig. 3–81 Checking Valve Fig. 3–82 Checking Valve
630, 631, 632 Loader
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
2 1
5
D–01650 D–01650
Fig. 3–85 Hydrostatic Motor Assembly
630, 631, 632 Loader

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. B–05138 B–05137
Fig. 3–86 Installing Seal Tool Fig. 3–87 Installing The Seal
5. Install the small diameter half of
the seal tool and push the seal
into the correct position (Fig.
3–87).
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 B–06771
Fig. 3–89 Installing Inner Seal Fig. 3–90 Installing Dust Seal
630, 631, 632 Loader
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 Installing Drive Shaft
630, 631, 632 Loader

The timing of the motor controls the
direction of rotation of the drive shaft Rotate Valve Clockwise
of the motor. The timing parts of the 1/2 Tooth to Engage Spline
motor are as follows (Fig. 3–93):
Anyone of 6 Ports
(a) Geroler (Item 1) Open to Outside of Valve 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).
Valve
19. Align the case drain hole and the Case Drain
three pressure holes in the Hole (2)
geroler ring with the same holes
in the mounting flange and
install the geroler assembly. 2
Make sure to keep the rollers in 3
position.
Valve Drive Valve Plate
20. Install the valve drive in the 1

geroler (Fig. 3–93, Item 2).
Pressure
Relief Hole (3) Geroler Geroler
NOTE: When looking through the Star
7 holes (Fig. 3–93, Item 5) in Ring
the valve plate, if you see a C–02384
roller in all the holes, it is Fig. 3–93 Timing The Motor
assembled incorrectly, the
motor will lock–up.
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
630, 631, 632 Loader
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 B–04645 B–05126
on the housing (Fig. 3–96).
Fig. 3–95 Installing Shuttle Valve 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 B–04649
Fig. 3–99 Installing Balance Plate Fig. 3–100 Installing Housing
630, 631, 632 Loader

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
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).
2 3
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 Fig. 3–102 Tighten Bolts
12253 & Below; 632–S/N 15450 & Below;
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.
FRONT
3. Leave enough clearance so the levers are 1/8’’ away from the bolts in the
pintle covers. OF LOADER
C–02767
*Fig. 3–102a Hose Routing
B–03256
Fig. 3–103 Installing Motor Cover
630, 631, 632 Loader
NOTE: There are three plastic
washers; two washers are Two Washers Between
the same and one is Centering Bar & Pintle Bar
different. The different
washer goes on the rear Centering Bar
pintle shaft (Fig. 3–104). 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
6. Install centering bar on the Washers Retainer Clip
transmission pump.
7. Install the other plastic washer

on front pump shaft. B–03028R
Fig. 3–104 Adjusting Neutral Position
8. Push the retainers on both pump
shafts. The clearance between
shoulder of pintle levers and
retainer clips must be .01–.02 .01’’ – .02’’
(Fig. 3–105). (0,254 – 0,508 mm)

9. Install centering bolt, spring and brass collar on centering bar and fasten Pintle
centering bolt to pump mount with locknut. 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.
Plastic Guide
14. Install right steering lever and connect auxiliary linkage. Tighten nut to 14 Centering
Bar B–03213
ft.–lbs. (19 Nm) torque.
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
630, 631, 632 Loader

22. Adjust foot pedals (Fig. 3–107).
This Point Of Foot Pedal
23. Install the operator cab. Must Be Even With Top
Of Transmission Case
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
WARNING 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.
W–2310–0398
A–02415R
26. Start engine. Run engine at full throttle. Fig. 3–107 Adjusting Pedals
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
14 5 9
15
12 16 4
13 17
10
7 6
11 1
18
3 2 9 8
5
4 E–01294
Fig. 3–108 Steering Linkage Assembly
630, 631, 632 Loader

3. Install the adjustment bars (Item
6) on the centering bar (Item 7)
630,631,632ServiceManual#6556454–HydrostaticSystemSection
Steering Linkages
and tighten with your hand only.
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.
Pintle
Adjust Bar Tight Bar Cam
7. Install the teflon guide (Item 11) in Adjustment 2.55–2.65’’
Against Both Cams (64,8–67,3 mm)
the centering bar (Item 7). Bar
8. Lubricate the cam surface (Item C–02544

1) (on the pintle lever) with Fig. 3–109 Centering Spring Adjustment
grease.
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.
630, 631, 632 Loader

DRIVE SYSTEM
Paragraph Page
Number Number
AXLE AND BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 4–1
BRAKE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3 4–2
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 4–1
DRIVE
SYSTEM
630, 631, 632 Loader

630, 631, 632 Loader

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 B–02811
Fig. 4–A Removing Axle Nut Fig. 4–B Removing Axle

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

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
630, 631, 632 Loader
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
B–02810 B–07679
available to give correct axle
end play. Fig. 4–2 Installing Outer Bearing Fig. 4–3 Installing Outer Race
The following tool must be needed to
install the bearing races.
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 B–07680 B–02770
position on the sprocket. Fig. 4–4 Installing Inner Race Fig. 4–5 Inner Halves
NOTE: The wide part of sprocket hub goes toward the inside for front axles
and toward the outside for rear axles.
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.
Be careful not to damage the gasket Spring

IMPORTANT when removing the transmission
covers. I–2118–1196
B–02772
Fig. 4–7 Installing Spring
630, 631, 632 Loader

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)
C–02376
thick to use for a handle (approximate dimensions).
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).
4. Remove brake disc. 2’’

1–3/4’’
NOTE: If brake discs cannot be removed between the two sprockets nuts, 3/8’’
it will be necessary to loosen one motor from the transmission case
and move the motor out 1/4’’ (6,4).
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 150 ft.–lbs. (203 Nm)
Brake
8. After tightening the sprocket nut, check to see that the brake disc will not Disc B–03021
come off the sprocket. If the disc will come off, loosen the sprocket nut and Fig. 4–10 Removing Brake Disc
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) Lobe Washer
torque.
To install new brake/puck assembly:
10. Remove the old brake/puck assembly from transmission cover.
Brake Disc B–03022

Fig. 4–11 Holding Brake Disc
630, 631, 632 Loader
11. Install the new brake block on the Cover
transmission 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 Brake Disc

transmission cover over the brake
discs. The gaskets will be aligned C–02372R
later (Fig. 4–12).
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
NOTE: Remove spacer from under Nut
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 C–02366

to 20 ft.–lbs. (27 Nm) torque.
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.
630, 631, 632 Loader

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) Fig. 4–14 Adjusting The Brake Lever
of threads are showing past end
of lock nut (Fig. 4–12).
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.
630, 631, 632 Loader

630,631,632ServiceManual#6556454–DriveSystemSection
630, 631, 632 Loader

MAIN FRAME
Paragraph Page
Number Number
BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 5–2
BOB–TACH FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6 5–3
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5 5–3
MAIN FRAME TO UPRIGHT FRAME BOLTS . . . . . . . . . . 5–4 5–3
PIVOT PIN REPLACEMENT OF THE LIFT ARMS . . . . . . 5–2 5–1
ROPS REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . 5–1 5–1
MAIN
FRAME
630, 631, 632 Loader

630, 631, 632 Loader

5 MAIN FRAME
5–1 ROPS REMOVAL AND
INSTALLATION (Fig. 5–1)
1. Stop engine and activate hydraulic
controls to release hydraulic
pressure in system.
2. Fasten a chain hoist to ROPS. Remove Bolts
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 Remove Bolts B–02800

Bobcat. Fig. 5–1 Removing ROPS
Be sure to install correct washer on

IMPORTANT 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)
Do not remove lift arms without

WARNING 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.
Pivot Pins
Be careful when removing pins in lift
WARNING cylinder. Keep cylinder from falling
when removing pins. W–2315–0498
B–02801
Fig. 5–3 Pivot Pin Replacement
630, 631, 632 Loader

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
5–3.2 Bob–Tach Removal (Fig. 5–5) Extend
Through
1. Lower lift arms and lower Slot
Bob–Tach to ground.
B–03893 B–02791
2. Stop engine and activate hydraulic Fig. 5–4 Checking Wedges Fig. 5–5 Removing Bob–Tach
controls to release hydraulic
pressure from system.
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
Fig. 5–6 Bob–Tach Pins
6. Install locking bolt in pin and tighten to 35–45 ft.–lbs. (48–61 Nm) torque.
5–3.4 Bob–Tach Pins

Lift Arm
Check bolts (Fig. 5–6, Item 1) at the 30 Stops
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
630, 631, 632 Loader

5–4 MAIN FRAME TO UPRIGHT
FRAME BOLTS
Check bolts (Fig. 5–8, Item 1) at the
Pre–Delivery Inspection and every 1
100 hours. Tighten bolts to 65–70
ft.–lbs. (88–95 Nm) torque.
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
630, 631, 632 Loader

630,631,632ServiceManual#6556454–MainFrameSection
630, 631, 632 Loader

ELECTRICAL SYSTEM
Paragraph Page
Number Number
ALTERNATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 6–24
ELECTRICAL CIRCUIT (631 & 632) . . . . . . . . . . . . . . . . . . 6–3 6–21
ELECTRICAL GENERAL INFORMATION . . . . . . . . . . . . . 6–2 6–19
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5 6–26
USING AN EXTRA BATTERY . . . . . . . . . . . . . . . . . . . . . . . . 6–1 6–1

ELECTRICAL
SYSTEM
630, 631, 632 Loader

630, 631, 632 Loader

121 of 284
122 of 284
123 of 284
124 of 284
125 of 284
126 of 284
127 of 284
128 of 284
129 of 284
130 of 284
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 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.
Never connect an extra battery to the

battery in the machine if the battery
WARNING 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.
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.
• Battery cables are connected
IMPORTANT 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
630, 631, 632 Loader

ROPS ELECTRICAL SYSTEM
(Harness P/N 6558859)
E–01188
630, 631, 632 Loader

ROPS WIRING DIAGRAM
E–01191
630, 631, 632 Loader

630 ENGINE ELECTRICAL SYSTEM
(S/N 14999 & Below)
Coil

Battery Starter
Solenoid
Flywheel
Alternator
E–01179
630, 631, 632 Loader

ENGINE WIRING DIAGRAM
630 (S/N 14999 & Below)
DIAGRAM
E–01198
630, 631, 632 Loader

ENGINE ELECTRICAL SYSTEM
631 (S/N 4997 12999 & Below)
Battery
Hydrostatic
Temperature

Alternator Switch
Hydrostatic
Pressure
Switch
Starter Pre–Heater
Oil Pressure Solenoid
Switch
E–01187
630, 631, 632 Loader

631 (S/N 4997 12999 & Below)
E–01199
630, 631, 632 Loader

ENGINE ELECTRICAL SYSTEM
Coil
Distributor
Carburetor
Valve Solenoid

Battery
Fuse On Earlier
Models Only
Starter
Alternator
Starter
E–01173R
630, 631, 632 Loader

E–01190
630, 631, 632 Loader

630, 631, 632 Loader

6–2 ELECTRICAL GENERAL
INFORMATION 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 Flywheel Stator
at connectors.
B–02958
5. Do Not operate the engine with the Fig. 6–1 Flywheel Alternator System (630)
battery disconnected from the
system.
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.
630, 631, 632 Loader

PROBLEM: BATTERY OVERCHARGE
TEST TEST RESULT POSSIBLE CAUSE & REMEDY
Test 1.0 With engine running at full 1.1 If voltage is over 15.0. 1.1 Regulator not functioning
RPM, check battery voltage properly. Replace module.
W/DC voltmeter.
1.2 If voltage is under 15.0. 1.2 Alternator functioning properly.
Check battery condition.
PROBLEM: LOW/NO CHARGE
Test 1.0 With engine running at full 1.1 If the charge rate increases– 1.1 Alternator functioning properly.
RPM, check battery W/DC Battery was fully charged.
meter. If voltage is greater
than 14 volts, put load on 1.2 If the charge rate does not 1.2 Proceed with Test 2.0.
battery to reduce voltage increase–
below 14 volts.
Test 2.0 Conditions and procedures 2–1 If the charge rate increases– 2.1 Regulator was at fault. Replace
the same as Test 1.0 the module.
except the regulator
module is disconnected. 2.2 If the charge rate does not 2.2 Regulator is not a fault.
increase– Continue with Test 3.0.

Test 3.0 Test conditions and 3.1 If the charge rate increases– 3.1 Rectifier module at fault.
procedure the same as 1.0 Permanently install new
except with new rectifier rectifier module.
module plugged in.
3.2 If the charge rate does not 3.2 Continue with Test 4.0.
increase–
Test 4.0 With engine stopped, 4.1 If one of the two voltages is 4.1 Te stator is faulty and must be
unplug all connectors zero or they are over 10% replaced.
between modules and apart–
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 REPLACE

CONNECTIONS STATOR
+ (Red) – (Black) METER VALUE IF . . .
Black #1 to Black #2 0.40 ohm
Black #1 to Eng. Gnd. 0.02 ohm
Black #2 to Eng. Gnd. 0.02 ohm 00 Indicates
Black #1 to Red 3.20 ohms Open Circuit
Black #2 to Red 2.80 ohms
630, 631, 632 Loader

142 of
Revised Mar. 85284 –6–20– 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 NORMAL

CONNECTIONS METER
+ (Red) – (Black) INDICATION
White lead to Black #1 No Continuity
Black #1 to White lead Continuity
White lead to Black #2 No Continuity
Black #2 to White lead 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 METER REPLACE

CONNECTIONS INDICATION MODULE
+ (Red) – (Black) (Good) If there is . . .
Red to Eng. Gnd. No Continuity Continuity
Eng. Gnd. to Red
Red to Black No Continuity Continuity
Black to Red
Black to Eng. Gnd.
Eng. Gnd. to Black 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).
630, 631, 632 Loader

143 of Mar.
Revised 284 85 –6–21– 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 electrolyte with
hydrometer.
Maintenance Free Type:
1. Check electrolyte ‘‘eye’’ if battery
has one.
Electrical system has incorrect 1. Check all wires for broken
ground. (Ammeter will show insulation.
discharge).
Alternator is not charging the battery. 1. Check the alternator for open
diode at alternator connector wire.

CHART B BATTERY OVER–CHARGE
POSSIBLE CAUSE &

TEST TEST RESULT REMEDY
With engine running at If voltage is over 15.0 Regulator not function–

full RPM, check battery ing properly. Replace as
voltage/DC voltmeter. 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.
630, 631, 632 Loader

6–3.3 ALTERNATOR BELT
ADJUSTMENT AND
REPLACEMENT (631, 632)
Adjustment: 1
1. Remove belt shield.
2. Check for correct freeplay

halfway between sheaves (Fig.
6–2 & Fig. 6–3) with 5 lbs. (2,27 1/2’’
kg) force. (13 mm)
3. Loosen alternator bolts and
move alternator for correct
adjustment.
Replacement:
1. Loosen alternator adjustment
bolts and move alternator to C–02299
loosen belt. Fig. 6–2 Belt Tension Adjustment (631)
2. Remove belt.
3. Install new belt. 1/2’’ Movement
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 Alternator
make adjustments as necessary.
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.
B–02661
3. Check cables to be sure both are Fig. 6–3 Belt Tension Adjustment (632)
clean and tight.
6–3.5 Check Alternator Wiring
No. 1 No. 2
1. Turn the key switch on. Terminal Terminal
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.
R
4. Find defect in wiring and make Terminal
repair.
Test Hole
5. Check voltage again. B–02113
Fig. 6–4 Alternator
630, 631, 632 Loader

6–3.6 Check Alternator Output

and rear corners of frame before
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.

Test Hole
6–4.2 Alternator Disassembly
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. A–02211
B–02113
6. Disconnect the diode trio. Fig. 6–5 Checking Regulator
630, 631, 632 Loader

6–4.3 Checking Rotor (Fig. 6–6) Check For Check For
Check For
Grounds Opens Grounds
1. Connect an ohmmeter between
one slip ring and shaft. There
must be maximum resistance.
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)

1. Connect a test light between the Check For Check For
center wire connection and one Shorts And Opens A–01857 Opens B–02108
of the outside wire connections. Fig. 6–6 Checking Rotor Coil Wires Fig. 6–7 Checking Stator Coil Wires
If the light does not come on,
there is a defect in the stator.
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
Do not use voltage which is more Fig. 6–8 Checking Diode Trio
than circuit voltage to check the
IMPORTANT diode trio or the rectifier on the
alternator.
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
2. Tighten three nuts on the connections. Heat Sink
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 B–02101
Heat Sink B–02102
Fig. 6–9 Checking Rectifier
630, 631, 632 Loader
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 B–02128
the machine falling and causing personal injury. 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
2. Remove nuts and washers that fasten the solenoid to the drive end of M
housing.
3. Remove the main part of the solenoid (Item 7). Remove the rubber seal (Item Cranking
14), plunger and spring assembly (Item 8) by lifting it from the top of the shift Motor
fork (Item 9).
NOTE: The plunger (Item 8) must also be replaced if the main part of the
solenoid is replaced. A–01991
*Fig. 6–12 Checking Solenoid
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 Jumper Wire
and remove the pin (Item 17).
Solenoid
6. Remove nuts and drive housing (Item 21) from starter frame (Item 25). Bat
S
7. Remove the shift fork (Item 9) from the starter frame. M Pin
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 Cranking
the armature (Item 26), complete with internal thrustwasher (Item 27) and Motor
drive assembly (Item 24), through the drive end of starter frame.
9. Remove thrustwasher (Item 27) from the commutator end of armature shaft.
A–01992
Fig. 6–13 Checking Starter
630, 631, 632 Loader

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.
630, 631, 632 Loader

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. Terminal
Covers
C–02448
4. Put a small amount of lubricant on the internal thrustwasher (Item 27) and Fig. 6–15 Starter Solenoid
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.
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).
630, 631, 632 Loader

ENGINE SERVICE
Paragraph Page
Number Number
DUET ENGINE (631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B 7B–1
FORD ENGINE (632) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C 7C–1
WISCONSIN (630) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A 7A–1

ENGINE
SERVICE
WISCONSIN (630)
DEUTZ (631)
FORD (632)
630, 631, 632 Loader

151 of 284 –7A––3– Service Manual
630, 631, 632 Loader

ENGINE SERVICE (WISCONSIN ENGINE–630)
Paragraph Page
Number Number
ACCESSORIES INSTALLATION . . . . . . . . . . . . . . . . . . . . 7A–37 7A–11
ACCESSORIES REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 7A–5 7A–4
AIR HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . 7A–35 7A–11
AIR HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–7 7A–4
CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 7A–22 7A–7

CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–19 7A–7
CAMSHAFT GEAR INSTALLATION . . . . . . . . . . . . . . . . . 7A–31 7A–10
CAMSHAFT GEAR RMOVAL . . . . . . . . . . . . . . . . . . . . . . . 7A–11 7A–4
CARBURETOR & MANIFOLD INSTALLATION . . . . . . . . 7A–34 7A–11

CARBURETOR & MANIFOLD REMOVAL . . . . . . . . . . . . 7A–8 7A–4
CARBURETOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–3 7A–3
CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . 7A–23 7A–7
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 7A–18 7A–7
CYLINDER BLOCK INSTALLATION . . . . . . . . . . . . . . . . . 7A–24 7A–8
CYLINDER BLOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . 7A–17 7A–6
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . 7A–33 7A–10

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 7A–9 7A–4
ENGINE IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 7A–2 7A–2

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–4 7A–3
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 7A–36 7A–11
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–6 7A–4
GEAR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . 7A–32 7A–10

GEAR COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–10 7A–4
GOVERNOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–38 7A–11
IDLER GEAR & SHAFT INSTALLATION . . . . . . . . . . . . . 7A–30 7A–10

IDLER GEAR & SHAFT REMOVAL . . . . . . . . . . . . . . . . . . 7A–12 7A–5 WISCONSIN (630)
OIL PAN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7S–29 7A–9

OIL PAN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–13 7A–5
OIL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 7A–28 7A–9
OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–14 7A–5
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 7A–25 7A–8
PISTONS & CONNECTING ROD INSTALLATION . . . . . 7A–27 7A–8
PISTONS & CONNECTING ROD REMOVAL . . . . . . . . . 7A–15 7A–5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–1 7A–1

VALVE TAPPET INSTALLATION . . . . . . . . . . . . . . . . . . . . 7A–21 7A–7
VALVE TAPPET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 7A–20 7A–7
VALVES AND SEAT INSERT INSTALLATION . . . . . . . . . 7A–26 7A–8
VALVES AND SEAT INSERT REMOVAL . . . . . . . . . . . . . 7A–16 7A–6
630, 631, 632 Loader

630, 631, 632 Loader

154 of 284 –7A–0– Service Manual
7A ENGINE SERVICE (WISCONSIN ENGINE – 630)
7A–1 TROUBLESHOOTING
PROBLEM CAUSE CORRECTION
Engine will not turn with starter. 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.
Engine turns with starter, but is difficult Wrong starting procedure. See Owner’s Manual for correct
to start. 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.
Engine has little power or runs rough. 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 make adjustment if
needed.
Dirty air cleaner. Check air cleaner.
Engine has lost compression. Overhaul the engine.
Engine overheats. Cooling system is dirty. Clean cooling system.
Engine air housing cover damaged or Check air housing covers.
missing.
Ignition system set wrong. Engine is Check ignition timing, Operate loader
overloaded. with engine at full throttle.
630, 631, 632 Loader

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 Timing
point block is on a high point of Sight Hole
the cam.
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 B–02975
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.
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).
If the engine is running below 1800

RPM when checking timing, the
automatic adjustment in the Distributor
WARNING distributor will not be fully forward.
Wrong timing can cause permanent A–01836
damage to the engine.
W– 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.

Spark
Plug
7A–2.3 Spark Plugs
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
630, 631, 632 Loader

7A–3 CARBURETOR SERVICE (Fig. 7A–4)
Adjustments Idler Adjustment
1. Adjust the throttle stop screw for correct maximum RPM by turning the screw Needle
Throttle
IN to increase RPM and OUT to decrease RPM. 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. C–02319
4. Push the control rod toward the carburetor (Fig. 7A–5). 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 Push Control
cotter pin. Governor
Rod 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).
Control
9. Install the spring in hole number 10. Rod Push
10. Connect a tachometer to the engine. Start engine and run at full throttle. 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).
B–02575
7A–4 REMOVAL OF ENGINE 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.
5. Disconnect the wiring at connector plug. 1/16
inch
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 Linkage Adjustment
630, 631, 632 Loader

7A–5 REMOVAL OF ACCESSORIES
Nut
Remove the engine oil filter, starter 12
and other installed parts.
10
7A–6 REMOVAL OF FLYWHEEL 8
6 Washer
1. Remove the flywheel nut and
washer (Fig. 7A–8). 4
2
2. Pull the flywheel off of the taper
on crankshaft. (Use a soft
hammer to loosen the flywheel
(Fig. 7A–9).
A–01833 B–02584
7A–7 REMOVAL OF AIR HOUSING
(FIG. 7A–10) Fig. 7A–7 Governor Linkage Fig. 7A–8 Remove Flywheel Nut
1. Remove the cylinder head

covers.
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 Cylinder
AND MANIFOLD Flywheel Head Covers
1. Remove the manifold nuts. Flywheel
A–01823
Shroud A–01841
2. Lift off the manifold section (Fig.
7A–11). Fig. 7A–9 Loosening Flywheel Fig. 7A–10 Removing Air Housing
7A–9 REMOVAL OF CYLINDER

HEADS 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.
HEADS
A–01830 B–02590
1. Disconnect the governor linkage. Fig. 7A–11 Remove Manifold Fig. 7A–12 Removing Cylinder Heads
2. Remove the gear cover bolts.
3. Drive out the two dowel pins (Fig.

7A–13).
4. Remove the cover. Dowel

Pin
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 A–01824
Fig. 7A–13 Remove Dowel Pins Fig. 7A–14 Remove Camshaft
630, 631, 632 Loader

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
Fig. 7A–15 Remove Idler Gear
7A–14 REMOVAL OF OIL PUMP
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 A–01834 A–01831
from the connecting rods.
Fig. 7A–16 Remove Oil Pan Fig. 7A–17 Remove Oil Pmmp
2. Hit the ends of the bolts lightly to
release the connecting rod cap
(Fig. 7A–18).
Connecting
Rod Cap
3. Remove carbon that can
interfere with removal of pistons
from the upper end of the
cylinders (Fig. 7A–19).
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
630, 631, 632 Loader
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). Piston
Assembly
2. Put a rag into the opening at the
bottom of the valve chamber so
the holding locks do not fall into B–02585
the engine oil pan.
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.

BLOCK
A–01827 A–02543
1. Remove the six nuts which hold
each cylinder block (Fig. 7A–23). Fig. 7A–21 Remove Valves Fig. 7A–22 Checking Valve Guides
2. Lift off the cylinder blocks.
B–02588
Fig. 7A–23 Remove Cylinder Block Nuts
630, 631, 632 Loader

7A–18 REMOVAL OF
CRANKSHAFT Crankshaft
1. Remove the six bolts in the main

bearing plate and remove the
plate (Fig. 7A–24).
2. Pull the crankshaft from the end Main Bearing

of the housing (Fig. 7A–24). Plate
7A–19 REMOVAL OF CAMSHAFT

1. Pull the camshaft from the
flywheel end of the engine (Fig.
7A–25). A–01843
Fig. 7A–24 Remove Crankshaft
7A–20 REMOVAL OF VALVE
TAPPETS
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. A–01846
Fig. 7A–25 Installing Camshaft
2. Push the camshaft in thru the flywheel end of the engine (Fig. 7A–25).
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.
B–02306
7A–23a Three Bearing Crankshaft
Fig. 7A–26 Crankshaft (3 Bearings) Seal
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 Push Number
race. Side of Bearing
Until Even With
3. When installing the third bearing, push on the number side of the bearing Support
until it is even with the inside of the bearing support (Fig. 7A–27).
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)
630, 631, 632 Loader
7A–24 INSTALLATION OF
CYLINDER BLOCKS 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.

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 B–02588 A–01826
ring, the 2nd ring is the Fig. 7A–28 Install Cylinder Block Fig. 7A–29 Install Piston Rings
compression ring and the 1st ring
is the compression ring (See Fig.
7A–30).
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 Scraper Ring
install new inserts when
necessary. 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 A–01844 A–01827

tappet clearance (See Section 8 Fig. 7A–30 Piston Ring Sequence Fig. 7A–31 Install Valves
‘‘Technical Data’’ for valve tappet
clearance).
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
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
A–01859
Fig. 7A–32 Install Rod Caps
630, 631, 632 Loader

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 B–02586
(Fig. 7A–32).
Fig. 7A–23 Install Pistons
5. Install the rod bearing nuts and
tighten them to 20–28 ft.–lbs.
7A–28 INSTALLATION OF OIL

PUMP
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. Wide Skirt
This Side Wide Skirt
7A–36). This Side
7A–29 OIL PAN INSTALLATION
1. Install the oil pan and install the

bolts. Tighten the bolts to 6–9
C–01660
Fig. 7A–34 Connect Piston Installation (4–Ring Pistons Only)
B–02580 A–01831
Fig. 7A–35 Install Oil Pump Fig. 7A–36 Fasten Oil Pump
630, 631, 632 Loader
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 B–02574 B–02576
mm). Fig. 7A–37 Install Gear & Shaft 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 B–02393
COVER
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.
CYLINDER HEAD
1. Install the cylinder heads. Plunger

Spring
2. Install the head bolts, using bolts C–01565
by length, according to the Fig. 7A–40 Installing Spring, Plunger & Gear
bosses on the cylinder heads
(Fig. 7A–42).
NOTE: Put oil on all of the cylinder 11 10

head bolts to protect them 12 1 9
from rust. 22
13 8
3. Tighten the head bolts in the
sequence shown in figure 21
7A–42. 14 7
2
4. Tighten the cylinder head bolts to
22–24 ft.–lbs. (30–33 Nm) 15 6
torque. 3 4 5 2
16 17 18 19
B–02578 B–02577
Fig. 7A–41 Install Cover Fig. 7A–42 Install Cylinder Head
630, 631, 632 Loader

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.
7A–35 INSTALLATION OF AIR

HOUSING
1. Install the bolts for holding the

flywheel housing to the gear
cover.
2. Install the bolts for holding the

A–01830
flywheel housing to the lower
cylinder covers (Fig. 7A–44). Fig. 7A–43 Install Manifold
3. Install the cylinder head covers

(Fig. 7A–44).
FLYWHEEL

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).
ACCESSORIES
Install the engine oil fiter, starter and
other parts removed during assembly.
7A–38 GOVERNOR SERVICE A–01841
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 Grind Corners
metal (at four places) from the two Flush With Taper
weights as shown in figure 7A–46.
Grind flush with taper on the weights.
Be sure to check the pivot points for
wear.
NOTE: Be sure to adjust governor

when you install it again
(See Section 7A–3.2 Page
7A–5).
B–02584 A–02629
Fig. 7A–45 Install Washer & Nut Fig. 7A–46 Governor Weights
630, 631, 632 Loader
630, 631, 632 Loader

631 ENGINE SERVICE (DEUTZ ENGINE–FL411D)
Paragraph Page
Number Number
BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–6 7B–8
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–12 7B–17
CYLINDER HEAD & VALVES . . . . . . . . . . . . . . . . . . . . . . . 7B–7 7B–8
CYLINDER, PISTONS, CONNECTING RODS . . . . . . . . 7B–8 7B–12
ENGINE FRONT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–10 7B–14

ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–4 7B–7
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–5 7B–7
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–13 7B–19

FUEL INJECTION NOZZLES . . . . . . . . . . . . . . . . . . . . . . . 7B–3 7B–7
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–1 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 Page
Number Number
BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–20 7B–27
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–26 7B–38
CAMSHAFT. CYLINDER HEAD & VALVE . . . . . . . . . . . . 7B–21 7B–28
CYLINDER, PISTONS, CONNECTING RODS . . . . . . . . 7B–22 7B–22
ENGINE FRONT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–24 7B–34

ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–18 7B–27
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–19 7B–27
DEUTZ (631)
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–27 7B–40
FUEL INJECTION NOZZLES . . . . . . . . . . . . . . . . . . . . . . . 7B–17 7B–26
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–16 7B–21
GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–25 7B–37
OIL PUMP, FILTER HOUSING AND RELIEF VALVE . . . 7B–23 7B–34

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–14 7B–20
(Deutz F2L411D) 630, 631, 632 Loader

167 of 284 –7B––1– Service Manual
168 of 284
(Deutz F2L411D) 630, 631, 632 Loader
–7B–0– Service Manual
7B ENGINE SERVICE (DEUTZ–F2L411D – 631)
7B–1 TROUBLESHOOTING
Engine will not turn over with starter. 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 disconnected wiring Connect or make replacement of
harness. wiring.
Defective starter or solenoid. Repairs as needed.
Engine fails to start or is difficult to Wrong starting procedure. Refer to ‘‘Starting Procedure’’ in the
start. 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).
Engine misses, runs irregularly or Fuel injection set wrong. Check timing.
stops.
Dirty fuel mixture, or restriction in fuel Clean as required.
filter or vent.
Poor compression. Check for loose cylinder head screws.
Water in the fuel. Make replacement of fuel.
(Deutz F2L411D) 630, 631, 632 Loader

169 of 284 –7B–1– Service Manual
Engine overheats. 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 Clean cooling fins and install the
covers removed. covers.
Dirty engine oil. Make replacement of engine oil.
Exhaust system has restriction. Correct as necessary.
Injection timing is wrong. Check fuel injection.
Too much engine vibration. Loose engine mount. Worn rubber Tighten bolts to correct torque.
mounts. Replace rubber mounts.
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. 5
Rear

2. Install the front mount on the Front
engine. Use a liquid adhesive Mount Mount
(”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 1 2
four bolts (Fig. 7B–1, Item 3) with
your hand only. 3
4
4. Install the engine into the loader.
5. Move the engine to align the 1

E–1186R
universal joint between the engine
and the hydrostatic pump. 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
170 of 284
(Deutz F2L411D) 630, 631, 632 Loader
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 Fig. 7B–3 Disconnecting Throttle Lever
screw on the excess fuel lever so the fuel button is fully down (Fig. 7B–4).
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.
C–02048
d. Repair of leak in fuel line.
Fig. 7B–5 Fuel Adjustment Screw
(Deutz F2L411D) 630, 631, 632 Loader

To vent air from fuel system: (Fig. Slotted Plug
7B–6).
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). 2
4. Move priming lever (2) until fuel C–01895 A–01593

comes from (1) free of bubbles.
Tighten fitting (1). Fig. 7B–6 Venting Fuel System 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).
KEEP Fuel Filter

IMPORTANT The Fuel System
CLEAN!
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 PI–01758
8 for correct pressure.) Check pressure by turning engine with starter. Fig. 7B–9 Fuel Pump Strainer
172 of 284
(Deutz F2L411D) 630, 631, 632 Loader
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]).
PI–02060 PI–01998
3. Close the throttle. Be sure the Fig. 7B–10 Pressure Indicator Tool Fig. 7B–11 Removing Injector Pump
excess fuel button is released.
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
PI–02043
out.
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 PI–02068
on top of gasket until the distance is 3.248–3.256 inches (82,5–82,7 mm)
(Fig. 7B–12 & Fig. 7B–13). 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 B–02201
Fig. 7B–14 Aligning Form With Groove Fig. 7B–15 Finding Top Dead Center (TDC)
(Deutz F2L411D) 630, 631, 632 Loader

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.
d. Use a flexible measure (tape PI–02052 B–02205
measure) to find the distance Fig. 7B–16 Marking Sheave W/Engine Cover Fig. 7B–17 Marking Halfway Position
between the marks on the pulley.
Put another mark exactly
between the other two marks on the pulley (Fig. 7B–17).
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 N–01983
show in the clear tube. When this happens, the 25° mark on the pulley will Fig. 7B–18 Marking Start Of Injection
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).
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 PI–02065
Fig. 7B–20 Removing Air From System Fig. 7B–21 Adjusting Injection Timing
174 of 284
(Deutz F2L411D) 630, 631, 632 Loader
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 PI–02062
Fig. 7B–25 Tool Fan checking Compression Fig. 7B–26 Cylinder Shims
(Deutz F2L411D) 630, 631, 632 Loader

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 PI–02029
Fig. 7B–27 Removing Blower Fig. 7B–28 Loosening Bolt
Use care not to damage the fan

IMPORTANT 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
Installation is the reverse of removal. PI–02061

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. Fig. 7B–31 Removing Bearing
176 of 284
(Deutz F2L411D) 630, 631, 632 Loader
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 PI–02011 PI–02012

holds the rocker arms in place
(Fig. 7B–32). Slide the bushings Fig. 7B–32 RemovingRocker Arm Screen Fig. 7B–33 Removing Bushing
out and lift the rocker arms out
(Fig. 7B–33).
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 PI–01982
Fig. 7B–34 Removing Valve Springs 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).
PI–02058 PI–02004
2. If the old valves are not badly
worn, they can be used again. Fig. 7B–36 Checking Valve Guide Clearance Fig. 7B–37 Removing Valve Guides
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).
3. When guides are good, cut or

grind the valve seats. PI–02005 PI–02006
Fig. 7B–38 Installing Snap Ring Fig. 7B–39 Using Reamer In Guide Bore
(Deutz F2L411D) 630, 631, 632 Loader

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 PI–01984 PI–02030
seat in place. First, heat the head Fig. 7B–40 Checking Valve Location Fig. 7B–41 Drilling Valve Seat
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–02031 PI–02007
Fig. 7B–42 Removing Valve Seat Fig. 7B–43 Washers & Gasket
5. Put the four washers and gasket
on the head and install the rocker
chamber (Fig. 7B–43 & 7B–44).
PI–02017 PI–02019
6. Measure the valve springs for Fig. 7B–44 Installing Rocker Chamber Fig. 7B–45 Checking Length of Valve Spring
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. PI–02018 PI–02020
7B–47).
Fig. 7B–46 Installing Washer & O–Ring Fig. 7B–47 Installing Valve Spring
178 of 284
(Deutz F2L411D) 630, 631, 632 Loader
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 PI–02027
Fig. 7B–48 Installing Rocker Fig. 7B–50 Checking Head Clearance
7B–7.4 Installation of Cylinder Head
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 PI–02064 PI–02047
at least one shim on each side of Fig. 7B–51 Checking Head Bolt Fig. 7B–51 Checking Alignment of Heads
spacer ring.) (See Fig. 7B–26).
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 PI–02037
5. Tighten the head bolts. Tool No. Fig. 7B–52 Tightening Head Bolts Fig. 7B–53 Seal Plate
4689 can be used to get correct
angle for tightening (Fig. 7B–52).
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 PI–02028
Fig. 7B–54 Installing Tube For Pushrod Fig. 7B–55 Set Screws For Tubes
(Deutz F2L411D) 630, 631, 632 Loader

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, PISTONS, Fig. 7B–56 Adjusting Rocker Arms
CONNECTING RODS
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 PI–02025 PI–02055
to be used again (Fig. 7B–57). Fig. 7B–57 Marking The Bearings 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 N–02026 PI–01991

and clean the piston thoroughly.
Check the following for wear or Fig. 7B–59 Checking Pin Bushing Fig. 7B–60 Checking Rod Bearing
damage:
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 PI–02016
Fig. 7B–61 Checking Rod Fig. 7B–62 Checking Cylinder Wall
180 of 284
(Deutz F2L411D) 630, 631, 632 Loader
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).
N–02014 PI–02048
3. Put the rings on the piston with the
mark on the rings upward. The Fig. 7B–63 Removing Pin Bushing Fig. 7B–64 Checking Ring Gap
chrome ring goes in the top
groove. Turn the rings so the gaps
are 120° apart.
4. Install the piston in the cylinder,

with the open side of the rod on the
pushrod side of cylinder (Fig.
7B–66). Pushrod
Side Of
Cylinder
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
PI–02053 PI–02056
bearing to crankshaft.
Fig. 7B–65 Installing Snap Ring 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) 630, 631, 632 Loader

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

PI–02041 PI–02067
The oil pressure relief valve location is Fig. 7B–69 Checking End Play Of Oil Pump Fig. 7B–70 Relief Valve For Oil Pressure
in the engine block (Fig. 7B–70). Do not
change the length of the spring and do
not add shims to the valve.
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
C–02038 PI–02039
7B–10.1 Removal
Fig. 7B–71 Removing Filter Housing 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.
PI–02040 PI–02045
Fig. 7B–73 O–Rings On Plugs Fig. 7B–74 Removing Cover Seal
7B–10.2 Disassembly & Inspection
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 PI–02046 PI–02071
o–ring (Fig. 7B–76). Fig. 7B–75 Installing Cover Seal Fig. 7B–76 Lubrication Of O–Ring
182 of 284
(Deutz F2L411D) 630, 631, 632 Loader
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 PI–02034
Fig. 7B–77 Setting Spring Tension 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 PI–02003 PI–01999

install the washer (Fig. 7B–79). Fig. 7B–79 Installing Shaft For Throttle 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).
PI–02000 PI–02001
4. Slide the shaft in more and install
the governor spring. Tighten the Fig. 7B–81 Lever Spring Fig. 7B–82 Installation Of Governor Spring
bolts which hold the spring in
position (Fig. 7B–82).
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
PI–02002 PI–02032
Fig. 7B–83 Installing Snap Rings Fig. 7B–84 Installing O–Rings on Shaft
(Deutz F2L411D) 630, 631, 632 Loader

183 of 284 –7B–15–
Revised Mar. 85 Service Manual
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 PI–01990
Fig. 7B–85 Installing Roll Pin Fig. 7B–86 Locating Dowel Pins
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.
5. Put the cover into place and

tighten the bolts evenly.
PI–01986 PI–01985
NOTE: The copper washer goes Fig. 7B–87 Installing Distributor Housing Fig. 7B–88 Installing Spring In Front Cover
under the bolt shown in
figure 7B–91.
6. Adjust the full and idle speeds

(See Section 8).
7B–11 GOVERNOR PI–01987 PI–02057
7B–11.1 Removal and Disassembly Fig. 7B–89 Camshaft End Clearance 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 and

disassemble the governor.
4. Inspect all parts for wear or PI–02054 B–02200

damage.
Fig. 7B–91 Installing Front Cover Fig. 7B–92 Removing Gear & Shaft
184 of 284
(Deutz F2L411D) 630, 631, 632 Loader
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).
PI–02008 PI–02009
3. Use a soft hammer to install the
shaft and gear into the engine Fig. 7B–93 Governor Bearing Assembly Fig. 7B–94 Installing Shims
block. Be sure the timing marks
are in alignment (Fig. 7B–96).
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
PI–02010 PI–01994
housing, the front cover and the
rocker arm covers. Fig. 7B–95 Retainer Ring 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

PI–01995 PI–02049
tappets out, and inspect all parts
for wear or damage. Fig. 7B–97 Installing Flyweights 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).
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.
B–02198
4. Install the fuel pump, oil pan and other parts removed.
Fig. 7B–99 Installing Thrust Washer
(Deutz F2L411D) 630, 631, 632 Loader

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 B–02202 PI–01988
thickness as those removed. Fig. 7B–101 Removing Flywheel & End Cover 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
Tang PI–01989
2. Put grease on the thrustwasher to Fig. 7B–103 Installing Bearing Fig. 7B–104 Installing Thrust Washer
hold it in position. Be sure the tang
on the washer is in the slot in the
block (Fig. 7B–104).
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. PI–02059 PI–01993
7B–106). Fig. 7B–105 Bearing Support Check Marks Fig. 7B–106 Installing Crankshaft
186 of 284
(Deutz F2L411D) 630, 631, 632 Loader
Revised Mar. 85 –7B–18– 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.
PI–01996
7. Tighten all bolts in the end plate and the bolt in the bearing support. Turn the
crankshaft to be sure it is free. 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 PI–01992
flywheel. 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) 630, 631, 632 Loader

7B–14 ENGINE SERVICE (DEUTZ F2L511) 631
7B–14.1 TROUBLESHOOTING
TROUBLESHOOTING THE ENGINE
Engine will not turn over with the Battery has lost charge. Charge battery. Check the
starter. 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.
harness. wiring.
Defective starter or solenoid. Repair as needed.
Engine fails to start or is difficult to Wrong starting procedure. Refer to “Starting Procedure” in the
start. 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 Correct as necessary.
water.
Damaged fuel lift pump. Make replacement of pump if
needed.
Hydraulic–hydrostatic load on Put all controls in neutral and warm
engine. oil reservoir during very low
temperatures.
Lever auxiliary pedal engaged. Put auxiliary lever in neutral.

Defect in fuel injection system. Check and make repairs as
needed.
Excess fuel function not working. Check solenoid and adjust.
Crankcase oil is thick. Use engine oil of correct viscosity
Engine misses, runs irregularly or Fuel injection set wrong. Check timing.
stops.
Dirty fuel mixture, or restriction in Clean as necessary.
fuel filter or vent.
Poor compression. Check for loose cylinder head bolts.
Water in the fuel. Drain and replace fuel. Replace fuel
filters.
(Deutz F2L511) 630, 631, 632 Loader

Engine overheats. Engine is overloaded. Operate in low range. Operate at
rated RPM.
Engine cooling fins are dirty. Remove covers and clean cooling
fans.
Engine has been operated with part Clean cooling fins and install the
of covers removed. covers.
Dirty engine oil. Make replacement of engine oil.
Injection timing is wrong. Check fuel injection.
Too much engine vibration. Loose engine mounts. Tighten mount bolts to correct
torque.
Worn rubber mounts. Replace 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.
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) 6
with your hand only. Rear

Front
Mount Mount
4. Install the engine into the loader.
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. 5 2
3
7. Install all four bolts (Fig. 7B–112, 4
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 1
on the bolts, but do not tighten E–1186R
them yet. Fig. 7B–1 Rubber Mounts
8. Check the alignment of the U–joint.

To check the alignment of U–joint:
(a) Remove the seat. Key Stock
(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.
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. B–03531
7B–114, Item 1). High idle must be 2625–2675 RPM. If not correct turn
adjustment screw. Fig. 7B–113 Disconnecting Throttle
(Deutz F2L511) 630, 631, 632 Loader

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 1
the top of the button and button
guide collar must be .0312 (.79
mm).
3. Check adjustment by pushing

down on the solenoid rod. The
lever must not bottom out on the 1
collar around the fuel excess
button.
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 B–03175R B–03218
the solenoid is in a full down
position when engaged. If Fig. 7B–114 Fuel Solenoid Installed Fig. 7B–115 Venting Fuel System
not there will be damage to
the solenoid.
7B–16.2 Venting Air from Fuel
System

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)
KEEP 1
IMPORTANT The Fuel System
CLEAN!
PI–01752
Fig. 7B–117 Fuel Lift Pump Strainer
(Deutz F2L511) 630, 631, 632 Loader

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).
B–03219
7B–16.6 Removal of Fuel Injection Pump 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
1. Put a new gasket on the pump
fastening surface.
(82,6–82,7 mm)
3.252–3.256
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 PI–02452
Fig. 7B–120 Removing Injector Pump Fig. 7B–121 Distance Camshaft to Gasket
(Deutz F2L511) 630, 631, 632 Loader

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 N–02413 N–02414
gaskets on both sides of the banjo
fitting. Fig. 7B–122 Adding or Removing Shims 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 N–02412
(closest to the pulley) is at the point of maximum compression (TDC). 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
Turn the pulley at a slow rate. Be Fig. 7B–125 Finding Top Dead Center (TDC)
IMPORTANT careful not to damage the valve or
piston.
(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° PI–02052
and remove the steel. Fig. 7B–126 Marking Sheave
(Deutz F2L511) 630, 631, 632 Loader

(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.
Turn the pulley at a slow rate. Be

IMPORTANT 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 N–01983
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 Fig. 7B–128 Marking Start of Injection
it is not loosen the injection pump and slide it in or out for adjustment of
injection timing (Fig. 7B–131).
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 Fig. 7B–129 Removing Air From System
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 N–02436
Fig. 7B–130 Aligned with Start of Injection Fig. 7B–131 Adjusting Injection Timing
(Deutz F2L511) 630, 631, 632 Loader

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.
Do not use steel brushes to clean the

IMPORTANT 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

NOTE: A new sealing gasket MUST be used each time an injector is PI–02464
replaced. Fig. 7B–135 Disassembly Of Injection Nozzle
(Deutz F2L511) 630, 631, 632 Loader

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
Do not use steel brushes to clean the

IMPORTANT injector tips.
1. Loosen the alternator to remove belts.
2. Remove the alternator bracket and the three bolts that hold the blower in N–02419
position (Fig. 7B–138). Lift the blower assembly off the engine. Fig. 7B–138 Removing Bolts
(Deutz F2L511) 630, 631, 632 Loader

1. Clamp the pulley of the cooling fan
in a vice with protective aluminum
jaws and unscrew the center bolt
(Fig. 7B–139).
N–02420 PI–02061
2. Remove the blower fan (Fig.
7B–140). Fig. 7B–139 Removing Center Bolt 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
N–02421
1. Fill the new bearing with high temperature bearing grease.
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.
N–02423
3. Remove the valve covers and the rocker arm brackets (Fig. 7B–143).
Fig. 7B–143 Removing Rocker Arm Bracket
(Deutz F2L511) 630, 631, 632 Loader

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 N–02424 N–02425

remove the push rod cover tubes.
Fig. 7B–144 Removing the Plugs 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 N–02426 N–02427
for damage (Fig. 7B–146). Light Fig. 7B–146 Checking Surface Fig. 7B–147 Checking Valve Depth
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 B–03488
tool kit (P/N 003–3409).
Fig. 7B–148 Removing Valve Guides
(a) 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) 630, 631, 632 Loader

(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 B–03486

correct length (Fig. 7B–153). Fig. 7B–152 Installing New Seat
4. Apply lubricant (oil) to valve stems and install them. Install the spring caps N–02410
(Fig. 7B–154), springs and retainer with a spring compressor.
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.
N–02428 N–02429
NOTE: The oil holes must be
aligned. Fig. 7B–154 Installing Spring Caps Fig. 7B–155 Checking Bushing
(Deutz F2L511) 630, 631, 632 Loader

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.
Use grease to hold the solder in

IMPORTANT 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) 630, 631, 632 Loader

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 N–02433
(Fig. 7B–162).
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 N–02409
Fig. 7B–161 Installing Push Rod Tubes Fig. 7B–162 Adjusting Rocker Arms
NOTE: Cylinders may be removed
with piston and connecting
rod in position. It is best to Metering
remove and install the piston Screw
rod and cylinder together to
prevent damage to parts.
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 PI–02025
Fig. 7B–163 Oil Metering Screw 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) 630, 631, 632 Loader

(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. N–02026 PI–01991
7B–170). Fig. 7B–166 Checking Pin Bushing 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 PI–02016
Fig. 7B–168 Check Rod Fig. 7B–169 Checking Cylinder Wall
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.
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 PI–02048
Fig. 7B–170 Removing Pin Bushing 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 N–02437
Fig. 7B–172 Piston Assembly Fig. 7B–173 Arrow on Piston
(Deutz F2L511) 630, 631, 632 Loader

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 N–02440
crankcase. Fig. 7B–175 Removing Bolt
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

N–02441
The oil pressure valve is located in the engine block. Do not charge the length of Fig. 7B–176 Removing Oil Pump
the spring and do not add shims to the valve.
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.
PI–02041
4. Lift off the front cover. Be careful not to lose the dowel pins. Fig. 7B–177 Checking End Play Of Oil Pump
(Deutz F2L511) 630, 631, 632 Loader

7B–24.2 Disassembly and
Inspection
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

PI–02442 PI–02040
governor shaft and install a new
one as shown in (Fig. 7B–180, Fig. 7B–178 End Plate and O–ring Location Fig. 7B–179 O–rings on Plugs
7B–181).
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 N–02443
4. If you replace the spring on the Fig. 7B–180 Removing Cover Seal Fig. 7B–181 Installing Cover Seal
excess fuel control, the spring
must be turned 3/4 of a turn to give
tension to the lever (Fig. B–183).
5. Remove the pin from the throttle

control lever, and remove the lever
from the shaft (Fig. 7B–184).
PI–02071 PI–02072
Fig. 7B–182 Lubrication of O–ring 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 N–02444 PI–02003
install the washer (Fig. 7B–185). Fig. 7B–184 Removing Pin Fig. 7B–185 Installing Shaft Bolt
(Deutz F2L511) 630, 631, 632 Loader

2. Put the shaft in position to install
3. Put the spring on and connect it as

shown in Figure 7B–187.
PI–01999 PI–02000
Fig. 7B–186 Control Arm Linkage Fig. 7B–187 Lever Spring
4. Move the shaft in more and install

the governor spring. Tighten the
bolts which hold the spring in

5. Install a snap ring on each side of
N–02445 N–02446
Fig. 7B–188 Installing Governor Spring 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 N–02447
Fig. 7B–190 Installing O–rings on Shaft Fig. 7B–191 Installing Roll Pin
1. Put dowel pins in front cover and
apply gasket sealant (Fig. Casket Dowel
7B–192). Sealant Pins
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 PI–02449
Fig. 7B–192 Location of Dowel Pins Fig. 7B–193 Checking End Clearance
(Deutz F2L511) 630, 631, 632 Loader

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
Fig. 7B–196 Installing Shims
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).
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 N–02453 N–02454

removed. Fig. 7B–197 Retainer Ring Fig. 7B–198 Alignment of Gears
(Deutz F2L511) 630, 631, 632 Loader

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 N–02457
Fig. 7B–199 Installing Flyweights 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
7B–26.2 Installation Fig. 7B–201 Installing Thrustwasher
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). Fig. 7B–203 Removing Center Main Bearing
(Deutz F2L511) 630, 631, 632 Loader

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 PI–01983
the holes in the block (Fig. 7B–207). Fig. 7B–207 Installing Crankshaft
(Deutz F2L511) 630, 631, 632 Loader

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
Fig. 7B–209 Checking End Play
To install the new gear, heat the ring to (200°C) and install onto a cool flywheel.
Installing Flywheel
1. Use new bolts (4) (Do not re–use old bolts).
2. Tighten to 22 ft.–lbs. (30 Nm) torque. Then 60° + 60° diagonally. N–02462
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 B–03539
Fig. 7B–211 Removing Ring Gear Fig. 7B–212 Fitting Oil Cooler
(Deutz F2L511) 630, 631, 632 Loader

208 of 284 –7B–40–
ENGINE SERVICE (FORD ENGINE–632)
Paragraph Page
Number Number
CAMSHAFT AND VALVE LIFTERS . . . . . . . . . . . . . . . . . . 7C–18 7C–23
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–27 7C–30
CARBURETOR REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–3 7C–9
CHECKS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . 7C–2 7C–2
CONNECTING ROD BEARINGS . . . . . . . . . . . . . . . . . . . . 7C–24 7C–27
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–26 7C–29
CRANKSHAFT REAR OIL SEAL . . . . . . . . . . . . . . . . . . . . 7C–22 7C–26
CYLINDERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–11 7C–18
ENGINE DIAGNOSIS & TESTING . . . . . . . . . . . . . . . . . . . 7C–4 7C–9
ENGINE FRONT COVER, TIMING
CHAIN & CRANKSHAFT SPROCKETS . . . . . . . . . . . . . 7C–15 7C–21
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–5 7C–10
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–7 7C–16
FLYWHEEL RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–19 7C–25
FRONT OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–16 7C–23
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–10 7C–18
MAIN BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–23 7C–26
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–20 7C–25
OIL PUMP, INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–6 7C–16
OIL PUMP, REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–21 7C–26

PISTONS AND CONNECTING RODS . . . . . . . . . . . . . . . 7C–25 7C–27
TIMING CHAIN TIGHTENER . . . . . . . . . . . . . . . . . . . . . . . 7C–17 7C–23
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–1 7C–1
VALVE PUSHROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–9 7C–17
VALVE ROCKER ARM COVER,
ROCKER ARM AND/OR SHAFT . . . . . . . . . . . . . . . . . . . 7C–8 7C–17
VALVE SPRING, RETAINER AND STEM
SEAL (CYLINDER HEAD INSTALLED) . . . . . . . . . . . . . . 7C–13 7C–20
VALVE SPRING, RETAINER AND STEM
SEAL (CYLINDER HEAD REMOVED) . . . . . . . . . . . . . . 7C–12 7C–20
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–14 7C–21
FORD (632)
630, 631, 632 Loader

209 of 284 –7C––1– Service Manual
210 of 284
630, 631, 632 Loader
–7C–0– 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

Starter will not turn engine. 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.

harness. wiring.
Starter or solenoid has defect. Make repair as needed.
Engine does not start or is difficult to Wrong starting procedure. Refer to “Starting Procedure” in the
start. Bobcat Owner’s Manual.
No fuel in tank. Add fuel.
Broken wire to the fuel shut–off Make repairs as needed.

solenoid.
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 load on Put all controls in neutral position

engine. 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,

630, 631, 632 Loader

211 of 284 –7C–1– Service Manual
Engine runs rough or engine stops. Faulty ignition system (spark plugs, Make repairs as necessary.
points, etc.) or incorrect timing.
Dirty fuel mixture, or restriction in Clean as necessary.
fuel filter or vent.
Poor compression. Check for loose cylinder head
screws or loose spark plugs.
Water in fuel. Make replacement of fuel.
Engine overheats. 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.
Injection timing is wrong. Make adjustment as necessary.
Coolant level is low. Add coolant.
Oil cooler has restriction. Find restriction and make
correction.

Valve In The Make Adjustment
Down Position To This Valve
7C–2 CHECKS AND ADJUSTMENTS #8 #1
#7 #2
7C–2.1 Engine Oil Pressure #6 #3
#5 #4
Engine oil pressure is good if the red warning light on the instrument panel is not #4 #5
illuminated. To check operation of warning light, turn ignition switch on. The #3 #6
warning light must be illuminated. #2 #7
#1 #8
Fig. 7C–12 Valve Adjustment Chart
7C–2.2 Valve Clearance (Fig. 7C–1) Feeler Gauge
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 A–02500
correct clearance.) Fig. 7C–1 Valve Adjustment
212 of 284
630, 631, 632 Loader
7C–2.3 Checking Engine
Compression
Maximum Minimum
1. Be sure crankcase oil is at correct PSI PSI
level and the battery has full 134 101
charge. Run the engine for 30 136 102
minutes at 1200 RPM or until the 138 104
engine is at normal operating
temperature. Turn the ignition 140 105
switch off. Remove all the spark 142 107
plugs and remove coil wire from 144 108
center of distributor cap. 146 110
148 111
150 113
152 114
2. Push the throttle lever all the way 154 115
to “fast” position and set the choke 156 117
so that the choke plate is open. 158 118
160 120
162 121
164 123
3. Install a compression gauge in 166 124
number 1 cylinder. 168 126
170 127
172 129
174 131
4. Turn the engine over at least 5 176 132
compression strokes and record 178 133

the highest reading. Remember 180 135
the approximate number of 182 136
strokes needed to get the highest 184 138
reading. 186 140
188 141
190 142
192 144
5. Repeat this test on each cylinder, 194 145
but instead of turning the engine 5 196 147
strokes, use the number of 198 148
strokes needed to get the highest
reading for number 1 cylinder. 200 150
202 151
204 153
206 154
208 156
210 157
212 158
214 160
216 162
Understanding the Results of the 218 163
Test 220 165
222 166
If the lowest reading is at least 75% of 224 168
the highest, the compression is normal 226 169
(See Chart on this page). 228 171
230 172
232 174
234 175
EXAMPLE: Seventy–five percent of 236 177
140 psi (the highest 238 178
compression reading) 240 180
is 105 psi. 242 181
244 183
246 184
248 186
250 187
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.
630, 631, 632 Loader

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 B–02662
leak between the cylinders.
Fig. 7C–3 Removing Belt Shield
NOTE: DO NOT operate engine with

1/2” Movement
this condition. This
condition can let engine oil
or engine coolant into the

cylinder and cause damage
to the engine.
1/4” Movement
7C–2.4 Carburetor, Throttle and

Governor Adjustments
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 Belt Tension Adjustment
3. Loosen governor fastening bolts

and make adjustment of belt to
give 1/4 inch (6,35 mm) freeplay
(Fig. 7C–4). Tighten governor Throttle
fastening bolts. Rod
4. Install belt shield.
1
NOTE: If only belt needs
adjustment, make
adjustment to linkage (Item
1).
5. Disconnect throttle
jackshaft–to–governor linkage 2
(Fig. 7C–5, Item 1).
Governor
6. Remove the throttle linkage from Control Arm
the governor control arm (Fig. B–02409
7C–5, Item 2). Fig. 7C–5 Throttle/GovernorAdjustment
214 of 284
630, 631, 632 Loader
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 Control Arm

and control arm–to–carburetor Stop

linkage as shown in figure
7C–8.
13. Hold the control arm and

linkage in this position and
tighten the two screws.
Move Control Arm
14. Start the engine and turn idle This Way
screw on the carburetor to set
the engine speed at 800 RPM
(Fig. 7C–9).
Throttle
15. Set the correct ignition timing. Linkage
(See 7C–2.7 “Ignition Timing” B–02400 B–02320
for correct procedure.)
Fig. 7C–7 Control Arm Stop 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 Throttle Idle
RPM. Adjustment
19. Turn control arm stop (Fig.

7C–7) until there is an increase B–02409a
of 25 RPM. Fig. 7C–9 Carburetor Adjustment
630, 631, 632 Loader

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 Fig. 7C–10 Governor Oil Check
each of the following:
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 BLACK
engine performance.
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 B
be more than 5000 ohms per inch (25,4 mm). When checking the resistance of D
the wires or setting ignition timing, do not puncture the wires. This can cause a Red
separation in the conductor. 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.
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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 Red
the battery to the coil is good.
6. If the voltmeter reading is greater than 6.9 volts, check the following:
Rotunda RE 16–31 or
The battery and cables for loose connections or corrosion. RE–27–44 Tester
Primary Wire
From Switch to
The primary insulation, broken wires, and loose or corroded connections. ”B” TERMINAL
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.
Black
2. Disconnect and ground the coil to distributor high voltage wire at the
distributor. PI–02144
Fig. 7C–12 Coil To Battery Test
630, 631, 632 Loader

3. With the ignition switch off, turn
the engine with an auxiliary CONDENSER STATIONARY
CONTACT
starter switch while reading the
voltage loss. 4 LOBE CAM
4. If the voltage loss is 0.4 volt or BREAKER ARM

CONTACT
less, the starting ignition circuit RETAINING
is good. SCREW
RETAINING
5. If the voltage loss is greater SCREW
than 0.4 volt, clean and tighten
the connections in the circuit or
make replacement of the wiring RUBBING
as necessary. 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

USE FIRST
NOTCH IN
PULLEY
ROTATION
BTDC FRONT CAP CLIP

POSITION
TDC
DISTRIBUTOR
POSITION COUNTERCLOCKWISE
VIEWED FROM LEFT SIDE OF ENGINE FIRING ORDER–1–2–3–4
Fig. 7C–14 Timing Marks
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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 Throttle
float assembly. Body
3. Put screwdriver against float

axle (3) at slotted side of float
hinge and push axle through 4
slotted side of bracket. Remove 3
axle from opposite side of hinge
and remove float assembly (4). 7
6
4. Remove fuel valve needle (5), 5
valve seat (6) and fiber washer
(7).
2
5. Use new parts in repair kit to
make replacement of above Solenoid
parts. 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. Fuel Body
2. Remove the rocker shaft

assembly. 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 Checking Camshaft Lift
630, 631, 632 Loader

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 Tool–4201–C PI–02148
Fig. 7C–17 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.
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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 TO REMOVE STOCK TO REMOVE
FROM TOP OF SEAT, STOCK FROM
use a sharp tool to break the sharp corner (ID) at the top of the valve guide. USE 30° WHEEL BOTTOM OF SEAT,
USE 60° 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 PI–02150
top. The finished valve seat must be in contact at approximately the center of the Fig. 7C–18 Grinding Valve Seat
valve face.
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”.
630, 631, 632 Loader

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).
PLACE PLASTIGAGE FULL CHECK WIDTH OF
3. Install cap and tighten bolts to correct torque. Do not turn crankshaft while WIDTH OF JOURNAL PLASTIGAGE
ABOUT 1/4 INCH
Plastigage is in place. OFF CENTER
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. MEASURING
PLASTIGAGE
INSTALLING 0.0015”
6. After bearing has been checked, remove Plastigage, put a light coat of PLASTIGAGE CLEARANCE
engine oil on the bearing surface and bearings. Install bearing cap. Tighten
cap bolts to correct torque. PI–02153
7. Do the above for all bearings that need replacement. 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).
B–03740
1. Find the size piston to be used by making a cylinder bore check. 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 PI–02154
damage to the ring or cylinder bore. Fig. 7C–21 Checking Gap Of Piston Ring
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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.
630, 631, 632 Loader

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).
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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.
Inspection A–02746
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”).
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.
630, 631, 632 Loader

Inspection
Inspect the cylinder walls for
damage, or other signs of wear.
Check the cylinder bore for FEELER
out–of–round and taper. Measure the GAUGE
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.
N–02164
Machine cylinders that are damaged Fig. 7C–24 Checking Outer Race To housing Clearance
or when out–of–round and/or taper or
more than the wear limits.
7C–6 OIL PUMP
7C–6.1 Cleaning FEELER
GAUGE
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 N–02165
and the outer race and rotor for
damage or wear. Fig. 7C–25 Checking Rotor Lobes–To–Race Clearance
Measure the outer race to housing

clearance (Fig. 7C–24). Check the
clearance between the outer race STRAIGHT EDGE
and the rotor lobes (Fig. 7C–25).
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 N–02166
outside diameter of the shaft and the
inside diameter of the housing Fig. 7C–26 Checking Rotor End Play
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.
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.
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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.
ROCKER SHAFT
PUSH ROD ASSEMBLY
6. Put the rocker cover and gasket on the cylinder head and fasten with the
screws. Tighten the screws to correct torque specifications.
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
CYLINDER HEAD
assembly.
N–02167
2. Remove the pushrods from their locations and keep them in correct order. Fig. 7C–28 Removing Rocker Arm Assy
630, 631, 632 Loader

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.
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.
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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
7C–11.2 Installation HEAD
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 N–02168
on the adjustment screws. Tighten the bolts evenly to specifications.
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.
630, 631, 632 Loader

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.

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.
Be sure piston is at top–dead–center

WARNING 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.
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.
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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
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.
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.
630, 631, 632 Loader

5. Remove the crankshaft sheave, using a puller.
6. Remove the four bolts that hold the oil pan to the timing chain cover. Remove CRANKSHAFT
SPROCKET
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
7C–15.3 Installation PI–02170
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).

CRANKSHAFT
SPROCKET
4. Install camshaft sprocket retainer and bolts, then tighten bolts to
specification. Bend locking tabs.
Tool–T70P–6150
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.
TIMING
CHAIN
7. Install the timing cover gasket,
oil pan gasket (if necessary)
and the end seal on the front CRANKSHAFT
cover with an oil resistant sealer GEAR
at the ends. Make alignment of TIMING MARK PI–02171
the cover (Fig. 7C–33) with tool. Fig. 7C–31 Installing Crankshaft Sprocket
Tighten the fastening bolts
evenly to specification and
remove the alignment tool.
Tighten the oil pan bolts to
specification. PI–02172
Fig. 7C–32 Timing Marks
8. Install the crankshaft sheave,
making alignment of the slot
with the crankshaft key. Tighten
the fastening bolt to
specifications.
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
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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
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. Handle Attaching
Bolt Cover Support N–02174
7C–17 TIMING CHAIN TIGHTENER
Fig. 7C–34 Installing Oil Seal In Front Cover
7C–17.1 Removal
1. Remove the timing chain cover (and oil pan if necessary).
TIMING CHAIN TENSIONER
2. Remove the timing chain tightener and arm by removing the two fastening
TIMING
bolts (Fig. 7C–35).

CHAIN
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 N–02175
2. Disconnect the fuel line at the fuel pump.
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.
630, 631, 632 Loader

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.
CAMSHAFT
N–02176
1. Install a new timing cover oil
seal (Fig. 7C–32). Fig. 7C–36 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.
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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.
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.
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.
630, 631, 632 Loader

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
7C–21.2 Installation BLOCK
1. Install new oil filter on the oil pump assembly.
2. Make sure the contact surfaces are clean of old gasket material, then install OIL PUMP
ASSEMBLY
the oil pump and filter assembly on the cylinder block, using a new gasket N–02178
with sealing compound and fasten with the three bolts. Tighten the bolts to Fig. 7C–37 Removing Oil Pump
specifications.
3. Check the oil level and add oil if necessary.

7C–22 CRANKSHAFT REAR OIL SEAL

7C–22.1 Removal
1. Remove the flywheel.
2. Remove the oil pan and gaskets. Handle REAR OIL SEAL
CARRIER
3. Remove the rear oil seal carrier and remove the seal. Tool–T70P–6165
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 GASKET
specifications. INSTALLING SEAL IN CARRIER
3. Put new gaskets on the block flange using sealing compound at each end. N–02179
Install the end seals with the chamfered end into the grooves, again using Fig. 7C–38 Installing Oil Seal For Crankshaft
a sealing compound and install the oil pan. Tighten the bolts to the correct
torque and in steps (Fig. 7C–39).
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.
The main bearing caps must be kept 1 2 3 4 5 6 7
in original positions. An arrow in the 15
18 L M N O P Q RC
cap points to the front of the engine. A
Location marks are on the caps.
The front cap has the letter “F”,
second cap has the number “2”, the 17 B
K J I H G F ED 16
center cap has the letter “C”, the
fourth cap has the number “4” and the 14 13 12 11 10 9 8
rear cap does not have a mark.
PI–02177
Fig. 7C–39 Tightening Sequence For Oil Pan Bolts
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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”).
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.
1. Install the upper and lower bearings in correct locations.

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.
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.
630, 631, 632 Loader

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.

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.

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.
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15. Connect the coolant hose to the
intake manifold.
16. Install the thermostat in the

cylinder head and install the CRANKSHAFT OIL SLINGER
gasket and thermostat housing.
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 N–02180

clearances to specification. 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.
CRANKSHAFT
THRUST
9. Remove the five main bearing caps and keep them in order so that each will WASHER
be installed in their original position.
10. Carefully remove the crankshaft from the cylinder block.

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 N–02181
“Main and Connecting Rod Bearings”).
Fig. 7C–41 Installing Thrust Washer
630, 631, 632 Loader

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
12. Install the engine in Bobcat. Fig. 7C–42 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.
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.
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TECHNICAL DATA
WISCONSIN (630)
Paragraph Page
Number Number
ENGINE SPECIFICATIONS DEUTZ (631)
(630 WISCONSIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–1
ENGINE SPECIFICATIONS
(631 DEUTZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–1 FORD (632)
ENGINE SPECIFICATIONS
(632 FORD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–1
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D–1
TECHNICAL DATA

TECHNICAL
DATA
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ENGINE SPECIFICATIONS, 630 (WISCONSIN)
WISCONSIN (630)
Paragraph Page
Number Number
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 8A–1 8A–1
LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 8A–3

TECHNICAL
DATA
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630 LOADER SPECIFICATIONS
55.1
90° 138.6 (1400)
(3521)
69.9
30° 108.6 (1775)
(2759)
21.6 42.6
(550) 86.3 (1082)
(2192)
39.9
75.6 (1013) 58
(1919) (1473)
8.6
27° (217)
26°
7.1 45.6
(180) 35.2 30.9 35.3
(894) (786) (897,4) (1152)
95.3
(2419) 53.5
120.2 (1359)
(3053) PI–02206

Dimensions are given for loader equipped with dirt Where applicable, specifications
bucket and standard tires and may vary with other conform to SAE standards and
bucket types. All dimensions are shown in inches. are subject to change without
Respective metric dimensions are given in notice.
millimeters enclosed by parentheses.
OPERATIONAL & PERFORMANCE Maximum Governed RPM ELECTRICAL

(Full Load) . . . . . . . . . . . . . . . . . . . . 2500 RPM
Operating Weight . . . . . . . . 3900 lbs. (1760 kg) Torque . . . . . . . 66 ft.–lbs. (89 Nm) @ 1800 RPM Alternator . . . . . . . . . . . . Flywheel type 25 amps.
Rated Operating Capacity . . 1000 lbs. (454 kg) Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . 4 Battery . . . . . . . . . . . . . 12 volt, 410 cold cranking
Lift Capacity to Bore/Stroke . . . . . . . . . . . 3.25/3.25(82,55/82,55) amps. @ 0°F (–17,8°C) 100 min. reserve
Maximum Height . . . . . . . . 1200 lbs. (544 kg) Displacement . . . . . . . . . . . 107.7 cu. in. (1,76 L) capacity
Tipping Load . . . . . . . . . . . . . 2050 lbs. (930 kg) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . Air Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt
Hydraulic Function Time: Lubrication . . . . . . . . . . Pressure system W/filter
Move Lift Arms to Crankcase Ventilation . . . . . . . . . . Vented fill cap
Maximum Height . . . . . . . . . . . . . 4 seconds Air Cleaner . . . . Dry replaceable paper element DRIVE SYSTEM
Lower Lift Arms from
Maximum Height . . . . . . . . . . . . 2.5 seconds LOADER HYDRAULICS Transmission . . . . Hydrostatic, infinitely variable,
Move Bucket to fully reversing (2).
Dumping Position . . . . . . . . . . . 2.2 seconds Pump . . . . . . . . . . . . . . . Engine driven vane type Final Drive . . . . . . . . . . #60 roller chain in sealed
Move Bucket to Pump Capacity . . . . . . . . 9.5 GPM (36 L/min.) @ chaincase with oil lubrication.
Retracted Position . . . . . . . . . . 1.6 seconds 2500 RPM
Travel Speed . . . . . 0 to 6.6 MPH (10,62 km/hr.) System Relief Setting . . . . 1950 PSI (12065 kPa) CAPACITIES
Controls: Hydraulic Fluid Filter . . . . . . . . . 40 micron bronze
Vehicle . . . . . Direction & speed controlled by filter in port block from suction, Fuel . . . . . . . . . . . . . . . . . . . . . . . 10 gal. (37,85 L)
two hand operated levers. replaceable element, 10 micron in Engine Lubricant Including Filter . . . 1 gal. (3,3 L)
Loader Functions . . . . . . Lift and tilt functions return line from cooler. Hydrauic System . . . . . . . . . . . . . 6 gal. (22,71 L)
controlled by separate foot pedals. Auxiliary Cylinder . . . . . . . . . . . . . . . . . . . . . . Doubleacting (Includes 3.5 gallons [13,26 L] reservoir)
function controlled by right steering lever. Chaincase Reservoir . . . . . . . . . 5 gal. (18,925 L)
Engine . . Hand lever throttle, manual choke &
key–type starter switch. .Lift Cyl. (2) Tilt Cyl. (1)
Main Drive . . . . . . . . . . . . . . . . . . . Hydrostatic Bore Dia. 2.00 (50,80) 3.25 (82,55) TIRES
Brakes . . . . . . . Mechanical disc., foot or hand Rod Dia. 1.25 (31,75) 1.50 (38,1)
operated pedal. Stroke 25.00 (635) 12.30 (312,42) Standard . . . . . . . . 7:00 x 15,6 Ply Rating Nylon
W/Bar Lug Tread
ENGINE (Engine Manufacturer’s Rating)
Control Valves . . . . . . . 3 spool, open center type
Make . . . . . . . . . . . . . . . . . . . . . . . . . Wisconsin W/float–detent on lift, detent MACHINE WEIGHT (W/out Attachments)
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VH4D on auxiliary
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline Fluid Lines . . . . . . . SAE standard full flow tubes, Shipping . . . . . . . . . . . . . . . 3400 lbs. (1532,3 kg)
Horsepower . . . . . . . . . . . . . . . . . 28 HP (21 Kw) hoses & fittings.
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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.

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)
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)
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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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0035–.0040 (0,089–0,102)
Piston Pin to Piston Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0000–.0008 (0,000–0,020)
Piston Ring Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010–.020 (0,254–0,508)
Piston Ring Side Clearance in Grooves:

Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .002–.0035 (0,051–0,089)
2nd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .001–.0025 (0,025–0,064)
3rd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .001–.0025 (0,025–0,064)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025–.004 (0,064–0,101)
8A–1.8 Ignition System

Breaker Point Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .018–.022 (0,458–0,559)
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .030 (0,762)
8A–1.9 Distributor Advance Characteristics

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 Ft. Lbs. Nm
Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–24 . . . . . . . . . . . . . . . . 30–33
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–30 . . . . . . . . . . . . . . . . 34–41
Manifold Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–23 . . . . . . . . . . . . . . . . 24–31
Timing Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–18 . . . . . . . . . . . . . . . . 19–24
Oil Pan Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9 . . . . . . . . . . . . . . . . . . . 8–12
Connecting Rod Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–28 . . . . . . . . . . . . . . . . 30–38
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–50 . . . . . . . . . . . . . . . . 54–68
Main Bearing Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–30 . . . . . . . . . . . . . . . . 34–41
Flywheel Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–60 . . . . . . . . . . . . . . . . 54–81
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ENGINE SPECIFICATIONS, 631 (DEUTZ)
Paragraph Page
Number Number
DEUTZ (631)
ENGINE SPECIFICATIONS (F2L411D) . . . . . . . . . . . . . . 8B–1 8B–1
LOADER SPECIFICATIONS (F2L411D) . . . . . . . . . . . . . . 8B–4
ENGINE SPECIFICATIONS (F2L511) . . . . . . . . . . . . . . . . 8B–2 8B–5
LOADER SPECIFICATIONS (F2L511 . . . . . . . . . . . . . . . . 8B–8
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55.1
90° 138.6 (1400)
(3521)
69.9
37° 108.6 (1775)
(2759)
21.6 42.6
(550) 86.3 (1082)
(2192)
39.9
75.6 (1013) 58
(1919) (1473)
8.6
27° (217)
26°
7.1 45.6
(180) 35.2 30.9 35.3
(894) (786) (897,4) (1152)
95.3
(2419) 53.5
120.2 (1359)
(3053) PI–02206


(Full Load) . . . . . . . . . . . . . . . . . . . . 2500 RPM
Operating Weight . . . . . . . . 3900 lbs. (1760 kg) Torque . . . . . 64.9 ft.–lbs. (88 Nm) @ 2000 RPM Alternator . . . . . . . . . . . . . . Belt driven, 42 amps.
Lift Capacity to Bore/Stroke . . . . . . . . . . 3.973/4.14(100/105,16) amps. @ 0°F (–17,8°C) 100 min. reserve
Maximum Height . . . . . . . . 1200 lbs. (540 kg) Displacement . . . . . . . . . . . . 101 in.# (1655 cm#) capacity
Tipping Load . . . . . . . . . . . . . 2100 lbs. (950 kg) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . Air Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt
Hydraulic Function Time: Lubrication . . . . . . . . . . . . . Pressure–gear pump
Move Lift Arms to Crankcase Ventilation . . . . . . . . Open breathing
Maximum Height . . . . . . . . . . . . 3.8 seconds Air Cleaner . . . . Dry replaceable paper element DRIVE SYSTEM
Dumping Position . . . . . . . . . . . 2.8 seconds Pump . . . . . . . . . . . . . . Engine driven vane pump Final Drive . . . . . . . . . . #80 roller chain in sealed
Move Bucket to Pump Capacity . . . . . . . . 9.5 GPM (36 L/min.) @ chaincase with oil lubrication;
Retracted Position . . . . . . . . . . 2.4 seconds 2500 RPM W/gear and chain reduction.
Travel Speed . . . . 0 to 6.6 MPH (0–10,6 km/hr.) System Relief Setting . . . . . 1950 PSI (12,1 kPa)
Controls: Hydraulic Fluid Filter . . . . . . . . . 40 micron bronze CAPACITIES
Vehicle . . . . . Direction & speed controlled by filter in port block from suction,
two hand operated levers. replaceable element, 10 micron in Fuel . . . . . . . . . . . . . . . . . . . . . . . . . 10 gal. (38 L)
Loader Functions . . . . . . Lift and tilt functions return line from cooler. Engine Lubricant Including Filter . . . 1 gal. (3,8 L)
controlled by separate foot pedals. Auxiliary Cylinder . . . . . . . . . . . . . . . . . . . . . . Doubleacting Hydraulic System . . . . . . . . . . . . . . . 6 gal. (23 L)
function controlled by right steering lever. (Includes 3.5 gallons [13,26 L] reservoir)
Engine . . . . Hand lever throttle, and key–type Chaincase Reservoir . . . . . . . . . . . . 5 gal. (19 L)
starter switch. .Lift Cyl. (2) Tilt Cyl. (1)
Main Drive . . . . . . . . . . . . . . . . . . . Hydrostatic Bore Dia. 2.00 (50,80) 3.25 (82,55)
Brakes . . . . . . . Mechanical disc., foot or hand Rod Dia. 1.25 (31,75) 1.50 (38,10) TIRES
operated pedal. Stroke 25.00 (635,0) 12.30 (312,42)
Standard . . . . . . . . 7:00 x 15,6 Ply Rating Nylon
ENGINE (Engine Manufacturer’s Rating) W/Bar Lug Tread
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deutz W/float–detent on lift, detent MACHINE WEIGHT (Without
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2L511 on auxiliary Attachments)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . #2 Diesel Fluid Lines . . . . . . . SAE standard full flow tubes,
Horsepower . . . . . . . . . . . . . . . 28.5 HP (21 Kw) hoses & fittings. Shipping . . . . . . . . . . . . . . . . . 4240 lbs. (1914 kg)
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251 of 284 –8B–1–
8B–1 ENGINE SPECIFICATIONS, 631 (Deutz)
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)

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.
252 of 284 (Deutz F2L411D) 630, 631, 632 Loader

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)
1st Undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4201–2.4209 (61,471–61,490)
2nd Undersize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4004–2.4012 (60,971–60,990)
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)
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.

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

(Deutz F2L411D) 630, 631, 632 Loader

253 of 284 –8B–3–
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°
Camshaft Bearing
Flange – ––– 25 ft.–lbs. (34 Nm)
Bearing Support 21.5 ft.–lbs. (29 Nm) 30° 60° – 60°
Blower Mounting
Bolts – ––– 25 ft.–lbs. (34 Nm)
V–Belt Pulley 21.5 ft.–lbs. (29 Nm) 90° – – 90°
Intake Manifold – ––– 11 ft.–lbs. (15 Nm)
Crankshaft Gear 21.5 ft.–lbs. (29 Nm) 30° 30° – 60°
Oil Suction Pipe – ––– 36 ft.–lbs. (49 Nm)

Flywheel 21.5 ft.–lbs. (29 Nm) 60° 30° – 90°
Rocker Arm Bolts 21.5 ft.–lbs. (29 Nm) 45° – – 45°
Balance Weight 21.5 ft.–lbs. (29 Nm) 30° 30° – 60°
* One flat on hex head equals 60°.
8B–1.8 Special Tools (Deutz)

100020 Compression checking tool
100030 Compression checking tool
101900 Angle of turn gauge for head bolts
101910 Angle of turn gauge for other bolts
110030 Tool for nozzle removal (Use with 150800)
121100 Valve spring tool
122100 Valve service tools
130300 Piston ring tool
130510 Piston ring compressor
131000 Wrist pin mandrel
139000 Heater for piston
141000 Puller for end cover and gears
143620 Tool for installing camshaft bearings
150010 Tool for reconditioning cylinder face on crankcase
150800 Puller tool
254 of 284
(Deutz F2L411D) 630, 631, 632 Loader
8B–2 ENGINE SPECIFICATIONS, 631 (Deutz)
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)

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)
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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)
(1st Undersize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.479–2.487 (63,471–63,490 mm)
(2nd Undersize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.479–2.480 (62,971–62,990 mm)
(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)
(2nd Undersize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3217–2.3224 (58,971–58,990 mm)
(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)
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.
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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 Capillary tube
003–0463 Extractor tool
003–0536 Slide hammer
003–0464 Adapter
003–1091 Spacer
003–1076 Compression Tester
003–0426 Removing scratches on cylinder head
003–3409 Valve seat removal tool (Kit)
003–0500 Degree scale to tighten heads
003–0501 To install spring on push rod tube
003–0430 Ring compressor
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ENGINE SPECIFICATIONS, 632 (FORD)
Paragraph Page
Number Number
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 8C–1 8C–1
LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 8C–6
FORD (632)
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55.1
100° 135.6 (1400)
(344.2)
69.7
30° 109.6 (1770)
(2768.6)
21.9 44.2
(556.3) 86.3 (1122.7)
(2192)
35.8
75.6 (909.3) 58.3
(1919) (1480.8)
8.1
27° (205.7)
26°
7.5 45.6
(190.5) 35.2 30.9 32.3
(894) (786) (820.4) (1152)
95.2
(2418) 53.4
120.2 (1356.3)
(3053) PI–02206


(Full Load) . . . . . . . . . . . . . . . . . . . . 2500 RPM
Operating Weight . . . . . . . . 3925 lbs. (1781 kg) Torque . . . . . . . 71 ft.–lbs. (96 Nm) @ 1800 RPM Alternator . . . . . . . . . . . . . . Belt driven, 37 amps.
Lift Capacity to Bore/Stroke . . . . . . 3.183/3.056(80,975/77,622) amps. @ 0°F (–18°C) 100 min. reserve
Maximum Height . . . . . . . . 1200 lbs. (540 kg) Displacement . . . . . . . . . . . . . . . 98 cu. in. (1,6 L) capacity
Tipping Load . . . . . . . . . . . . . 2100 lbs. (950 kg) Cooling System . . . . . . . . . . . . . . . . . . . . . . Liquid Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt
Hydraulic Function Time: Crankcase Ventilation . . . . . . . . . . Filter rod vent
Move Lift Arms to Air Cleaner . . . . Dry replaceable paper element
Maximum Height . . . . . . . . . . . . . 4 seconds DRIVE SYSTEM
Dumping Position . . . . . . . . . . . 2.2 seconds Pump . . . . . . . . . . . . . . . Engine driven vane type Final Drive . . . . . . . . . . #60 roller chain in sealed
Move Bucket to Pump Capacity . . . . . . . . 9.5 GPM (36 L/min.) @ chaincase with oil lubrication;
Retracted Position . . . . . . . . . . 1.6 seconds 2500 RPM
Travel Speed . . . 0 to 6.6 MPH (0–10,52 km/hr.) System Relief Setting 1950 PSI (123,04 kg. cm#) CAPACITIES
Controls: Hydraulic Fluid Filter . . . . . . . . . 40 micron bronze
Vehicle . . . . . Direction & speed controlled by filter in port block from suction, Cooling System . . . . . . . . . . . . . . . . 10 qts. (9,5 L)
two hand operated levers. replaceable element, 10 micron in Fuel . . . . . . . . . . . . . . . . . . . . . . . 10 gal. (37,85 L)
Loader Functions . . . . . . Lift and tilt functions return line from cooler. Engine Lubricant Including Filter . . . 1 gal. (3,8 L)
controlled by separate foot pedals. Auxiliary Cylinder . . . . . . . . . . . . . . . . . . . . . . Doubleacting Hydraulic System . . . . . . . . . . . . . 6 gal. (22,71 L)
function controlled by right steering lever. (Includes 3.5 gallons [13,26 L] reservoir)
Engine . . Hand lever throttle, manual choke & Chaincase Reservoir . . . . . . . . . 5 gal. (18,925 L)
key–type starter switch. .Lift Cyl. (2) Tilt Cyl. (1)
Main Drive . . . . . . . . . . . . . . . . . . . Hydrostatic Bore Dia. 2.00 (50,80) 3.25 (82,55)
Brakes . . . . . . . Mechanical disc., foot or hand Rod Dia. 1.25 (31,75) 1.50 (38,1) TIRES
operated pedal. Stroke 25.00 (635) 12.30 (312,42)
Standard . . . . . . . . 7:00 x 15,6 Ply Rating Nylon
ENGINE (Engine Manufacturer’s Rating) W/Bar Lug Tread
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ford W/float–detent on lift, detent MACHINE WEIGHT (W/out Attachments)
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–98 on auxiliary
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline Fluid Lines . . . . . . . SAE standard full flow tubes, Shipping . . . . . . . . . . . . . . . 3400 lbs. (1532,3 kg)
Horsepower . . . . . . . . . . . . . . . . . 30 HP (22 Kw) hoses & fittings.
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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.

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

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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)
630, 631, 632 Loader

263 of 284 –8C–3–
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)
264 of 284
630, 631, 632 Loader
Revised Mar. 85 –8C–4– Service Manual
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 CENTRIFUGAL PLUS CENTRIFUGAL PLUS VACUUM

RPM INITIAL ADVANCE PLUS INITIAL ADVANCE
850 10–12° 28–36°
1000 10–12° 28–36°
1200 10–15° 28–39°
1400 11–17° 29–41°
1600 13–19° 31–43°
2000 18–24° 36–48°
2600 22–28° 40–52°
*All above values are readings as seen at crankshaft timing marks.
8C–1.13 Starter
Solenoid Actuated Starter Motor Starter Brushes
Normal
Dia. In Current Draw Engine No. Wear Spring
Inches Under Normal Cranking Load Limit In Tension
(Metric) Load (Amps) Speed (RPM) (Amps) Inches (Ounces
3–1/2 (88,9) 135–250 140–180 65 5/16 (1,8) 28
630, 631, 632 Loader

265 of 284 –8C–5–
8C–1.14 Torque Specifications for Engine
Item Ft.–Lbs. Nm
Camshaft Sprocket to Camshaft Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15 16–20
Camshaft Thrust Plate Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 3.5
Connecting Rod Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30–35 41–47
Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 1–20–30 27–41
Step 2–50–55 68–75
Step 3–65–70 88–95
Crankshaft Pulley Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–28 33–38
Cylinder Front Cover Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7 7–9,5
Carburetor Attaching Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15 16–20
Chain Tension Support to
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7 7–9,5
Distributor to Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7 7–9,5
Distributor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 2,7–4,1
Exhaust Manifold to Cylinder
Head Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–18 20–24
Separator Clamping Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9 8–12
Flywheel to Crankshaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45–50 61–68
Fuel Pump to Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15 16–20
Alternator Mounting to Cylinder
Block Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–25 27–34
Intake Manifold to Cylinder
Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–18 20–24
Main Bearing Cap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65–70 88–95
Oil Pump to Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15 16–20
Oil Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–25 27–34

Oil Pan to Cylinder Block Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8 8–11
Oil Pump Cover to Oil Pump Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7 7–9,5
Rear Oil Seal Retainer to
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15 16–20
Rocker Cover to Cylinder
Head Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5–3.5 3,4–4,7
Rocker Shaft Support Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–30 34–41
Spark Plug to Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–28 30–38
Water Outlet Connection to
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15 16–20
Water Pump to Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7 7–9,5
Water Pump to Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–15 16–20
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2 turn after
gasket contacts
surface
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
266 of 284
630, 631, 632 Loader
TECHNICAL DATA
Paragraph Page
Number Number
DECIMAL & MILLIMETER
EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D–3
HYDRAULIC/HYDROSTATIC TRANSMISSION
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D–2 8D–1
LOADER TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . 8D–1 8D–1
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D–3 8D–1
STANDARD TORQUE SPECIFICATIONS TECHNICAL DATA
FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D–2
U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . . . . . 8D–3
630, 631, 632 Loader

267 of 284 –8D––1– Service Manual
268 of 284
630, 631, 632 Loader
–8D–0– 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
630, 631, 632 Loader

269 of 284 –8D–1–
CONVERSIONS
Decimal And Millimeter Equivalents
FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 0.015625 — 0.397 33/64 0.515625 — 13.097
1/32 0.03125 — 0.794 17/32 0.53125 — 13.494
3/64 0.046875 — 1.191 35/64 0.546875 — 13.891
1/16 0.0625 — 1.588 9/16 0.5625 — 14.288
5/64 0.078125 — 1.984 37/64 0.578125 — 14.684
3/32 0.09375 — 2.381 19/32 0.59375 — 15.081
7/64 0.109375 — 2.778 39/64 0.609375 — 15.478
1/8 0.1250 — 3.175 5/8 0.6250 — 15.875
9/64 0.140625 — 3.572 41/64 0.640625 — 16.272
5/32 0.15625 — 3.969 21/32 0.65625 — 16.669
11/64 0.171875 — 4.366 43/64 0.671875 — 17.066
3/16 0.1876 — 4.762 11/16 0.6875 — 17.462
13/64 0.203125 — 5.159 45/64 0.703125 — 17.859
7/32 0.21875 — 5.556 23/32 0.71875 — 18.256
15/64 0.234375 — 5.953 47/64 0.734375 — 18.653
1/4 0.2500 — 6.350 3/4 0.7500 — 19.050
17/64 0.265625 — 6.747 49/64 0.765625 — 19.447
9/32 0.28125 — 7.144 25/32 0.78125 — 19.844
19/64 0.296875 — 7.541 51/64 0.796875 — 20.241
5/16 0.3125 — 7.938 13/16 0.8125 — 20.638
21/64 0.328125 — 8.334 53/64 0.828125 — 21.034
11/32 0.34375 — 8.731 27/32 0.84375 — 21.431

23/64 0.359375 — 9.128 55/64 0.859375 — 21.828
3/8 0.3750 — 9.525 7/8 0.8750 — 22.225
25/64 0.390625 — 9.922 57/64 0.890625 — 22.622
13/32 0.40625 — 10.319 29/32 0.90625 — 23.019
27/64 0.421875 — 10.716 59/64 0.921875 — 23.416
7/16 0.4375 — 11.112 15/16 0.9375 — 23.812
29/64 0.453125 — 11.509 61/64 0.953125 — 24.209
15/32 0.46875 — 11.906 31/32 0.96875 — 24.606
31/64 0.484375 — 12.303 63/64 0.984375 — 25.003
1/2 0.5000 — 12.700 1 1.000 — 25.400
1 mm = 0.03937’’ 0.001’’ = 0.0254 mm

U.S. To Metric Conversion
TO CONVERT INTO MULTIPLY BY
LINEAR Miles Kilometers 1.609
MEASUREMENT Yards Meters 0.9144
Feet Meters 0.3048
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Millimeters 25.4
AREA Square Miles Square Kilometers 2.59
Square Feet Square Meters 0.0929
Square Inches Square Centimeters 6.452
Acre Hectare 0.4047
VOLUME Cubic Yards Cubic Meters 0.7646
Cubic Feet Cubic Meters 0.02832
Cubic Inches Cubic Centimeters 16.39
WEIGHT Tons (Short) Metric Tons 0.9078
Pounds Kilograms 0.4536
Ounces (Avdp.) Grams 28.3495
PRESSURE Pounds/Sq. In. Kilopascal 6.895
WORK Foot–Pounds Newton–Metre 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LIQUID FLOW Gallons/Minute Liters/Minute 3.785
TEMPERATURE Fahrenheit Celsius 1.Subtract 32°
2. Multiply by 5/9
270 of 284
630, 631, 632 Loader
–8D–2– Service Manual
ALPHABETICAL INDEX
Paragraph Page
Number Number
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 9–1

ALPHABETICAL
INDEX
630, 631, 632 Loader

272 of 284
630, 631, 632 Loader
–9–0– Service Manual
9 ALPHABETICAL INDEX
Subject Page Subject Page
Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 Crankshaft End Play (632) . . . . . . . . . . . . . . . . . . . 7C–10

Air Housing, installation of (630) . . . . . . . . . . . . . . . 7A–13 Crankshaft Inspection, F2L411D (631) . . . . . . . . . 7B–18
Air Housing, removal of (630) . . . . . . . . . . . . . . . . . . 7A–6 Crankshaft Inspection, F2L511D (631) . . . . . . . . . 7B–39
Alternator Assembly & Installation . . . . . . . . . . . . . . 6–26 Crankshaft, installation of (630) . . . . . . . . . . . . . . . . 7A–9
Alternator Belt, adjustment & replacement . . . . . . . 6–23 Crankshaft Journals, reconditioning (632) . . . . . . . 7C–11
Alternator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6–24 Crankshaft, removal of (630) . . . . . . . . . . . . . . . . . . . 7A–9
Alternator Output, check . . . . . . . . . . . . . . . . . . . . . . 6–24 Crankshaft Removal, F2L411D (631) . . . . . . . . . . . 7B–18
Alternator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–24 Crankshaft Removal, F2L511D (631) . . . . . . . . . . . 7B–38
Alternator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–24 Crankshaft Sprockets (632) . . . . . . . . . . . . . . . . . . 7C–21
Alternator Wiring, check . . . . . . . . . . . . . . . . . . . . . . . 6–23 Crankshaft, three bearing (630) . . . . . . . . . . . . . . . . 7A–9
Axle Assembly & Installation . . . . . . . . . . . . . . . . . . . . 4–2 Cylinder Block (632) . . . . . . . . . . . . . . . . . 7C–13, 7C–15
Axles & Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 Cylinder Block, installation of (630) . . . . . . . . . . . . 7A–10
Axle & Bearing, removal . . . . . . . . . . . . . . . . . . . . . . . . 4–1 Cylinder Block, removal of (630) . . . . . . . . . . . . . . . . 7A–8
Cylinder Head (632) . . . . . . . . . . . 7C–10, 7C–13, 7C–18
Battery & Cables, check condition of . . . . . . . . . . . . 6–23 Cylinder Head, installation of (630) . . . . . . . . . . . . . 7A–12
Battery, installing new . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 Cylinder Head, installation of F2L411D (631) . . . . 7B–11
Battery, using an extra . . . . . . . . . . . . . . . . . . . 1–13, 6–1 Cylinder Heads, removal of (630) . . . . . . . . . . . . . . . 7A–6
Bearings, camshaft (632) . . . . . . . . . . . . . . . . . . . . 7C–30 Cylinder Head & Valves, F2L411D (631) . . . . . . . . . 7B–8
Bearings, connecting rods (632) . . . . . . . . . . . . . . 7C–27 Cylinder Head & Valve, F2L511D (631) . . . . . . . . . 7B–28
Bearings, main (632) . . . . . . . . . . . . . . . . . . . . . . . . 7C–26 Cylinders, Pistons & Connecting Rods,
Bearings, Main & Connecting Rod (632) . . . . . . . 7C–15 F2L411D (631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–12
Blower Fan, F2L411D (631) . . . . . . . . . . . . . . . . . . . . 7B–8 Cylinders, Pistons & Connecting Rods,
Blower Fan, F2L511D (631) . . . . . . . . . . . . . . . . . . . 7B–27 F2L511D (631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–32
Bob–Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2

Bob–Tach Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 Detent Spool, repair . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
Bob–Tach Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Diode Trio, checking . . . . . . . . . . . . . . . . . . . . . . . . . . 6–25
Bob–Tach Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Distributor Maintenance . . . . . . . . . . . . . . . . . . . . . . . 7A–4
Bob–Tach & Pivot Pins . . . . . . . . . . . . . . . . . . . . . . . . 1–16 Drive Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
Bob–Tach Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Drive, final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
Bob–Tach Wedges, checking . . . . . . . . . . . . . . . . . . . 5–2
Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 Electrical Circuit (631, 632) . . . . . . . . . . . . . . . . . . . . 6–21
Breather, crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 Electrical Connector, ROPS . . . . . . . . . . . . . . . . . . . . 6–22
Brush Replacement (Starter) . . . . . . . . . . . . . . . . . . . 6–28 Electrical General Information . . . . . . . . . . . . . . . . . . 6–19
By–Pass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
Electrical Wiring, check . . . . . . . . . . . . . . . . . . . . . . . 6–28
Camshaft (632) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–14 Engine Compression, checking (632) . . . . . . . . . . . 7C–3
Camshaft, F2L411D (631) . . . . . . . . . . . . . . . . . . . . 7B–17 Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . 1–10
Camshaft, F2L511D (631) . . . . . . . . . . . . . . . . . . . . 7B–38 Engine Diagnosis & Testing (632) . . . . . . . . . . . . . . . 7C–9
Camshaft End Play (632) . . . . . . . . . . . . . . . . . . . . 7C–10 Engine Electrical System . . . . . . . . . . . . . . . . . . . . . . 1–11
Camshaft, installation of (630) . . . . . . . . . . . . . . . . . . 7A–9 Engine Front Cover, F2L411D (631) . . . . . . . . . . . . 7B–14
Camshaft Gear, installation of (630) . . . . . . . . . . . . 7A–12 Engine Front Cover, F2L511D (631) . . . . . . . . . . . . 7B–34
Camshaft, removal of (630) . . . . . . . . . . . . . . 7A–6, 7A–9 Engine Front Cover (632) . . . . . . . . . . . . . . . . . . . . 7C–21
Camshaft Repair (632) . . . . . . . . . . . . . . . . . . . . . . . 7C–11 Engine Ignition System (630) . . . . . . . . . . . . . . . . . . 7A–4
Camshaft & Valve Lifters (632) . . . . . . . . . . . . . . . 7C–23 Engine Information, F2L411D (631) . . . . . . . . . . . . . 7B–7
Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 1–10 Engine Information, F2L511D (631) . . . . . . . . . . . . 7B–27
Carburetor & Manifold, installation of (630) . . . . . . 7A–13 Engine Mounts, F2L411D (631) . . . . . . . . . . . . . . . . 7B–2
Carburetor & Manifold, removal of (630) . . . . . . . . . 7A–6 Engine Mounts, F2L511D (631) . . . . . . . . . . . . . . . 7B–21
Carburetor Repair (632) . . . . . . . . . . . . . . . . . . . . . . . 7C–9 Engine Muffler, the . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17
Carburetor Service (630) . . . . . . . . . . . . . . . . . . . . . . 7A–5 Engine Oil & Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
Carburetor, Throttle & Governor Adjustment (632) 7C–4 Engine Oil Pressure (632) . . . . . . . . . . . . . . . . . . . . . 7C–2
Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 Engine Overhaul (632) . . . . . . . . . . . . . . . . . . . . . . 7C–10
Connecting Rod (632) . . . . . . . . . . . . . . . . . . . . . . . 7C–14 Engine, removal of (630) . . . . . . . . . . . . . . . . . . . . . . 7A–5
Connections, 37° Flare . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 Engine Removal, F2L411D (631) . . . . . . . . . . . . . . . 7B–7
Connection, straight thread o–ring . . . . . . . . . . . . . . . 2–7 Engine Removal, F2L511D (631) . . . . . . . . . . . . . . 7B–27
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 Engine, removal of (632) . . . . . . . . . . . . . . . . . . . . 7C–16
Control Valve, assembling . . . . . . . . . . . . . . . . . . . . . . 2–9 Engine Service (General) . . . . . . . . . . . . . . . . . . . . . . . 1–4
Control Valve, disassembly & inspection of . . . . . . . . 2–9 Engine Service (630) . . . . . . . . . . . . . . . . . . . . . . . . . 7A–1
Control Valve, removing . . . . . . . . . . . . . . . . . . . . . . . . 2–9 Engine Service, F2L411D (631) . . . . . . . . . . . . . . . . 7B–1
Crankshaft (632) . . . . . . . . . . . . . . 7C–11, 7C–14, 7C–29 Engine Service, F2L511D (631) . . . . . . . . . . . . . . . 7B–20
Crankshaft Assembly, F2L411D (631) . . . . . . . . . . 7B–18 Engine Service Ford Engine (632) . . . . . . . . . . . . . . 7C–1
Crankshaft Assembly, F2L511D (631) . . . . . . . . . . 7B–39
Crankshaft Connecting Rod Bearing, to check (632)7C–11 Filter Housing, F2L411D (631) . . . . . . . . . . . . . . . . 7B–14
630, 631, 632 Loader

9 ALPHABETICAL INDEX (Cont’d)
Float Adjustment (630) . . . . . . . . . . . . . . . . . . . . . . . . 7A–5 Hydrostatic Motor Inspection (631 & 632
Flywheel (632) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–14 S/N 15321 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . 3–38
Flywheel, F2L411D (631) . . . . . . . . . . . . . . . . . . . . . 7B–19 Hydrostatic Motor, installing (630 & 632
Flywheel, F2L511D (631) . . . . . . . . . . . . . . . . . . . . . 7B–40 S/N 15320 & Below) . . . . . . . . . . . . . . . . . . . . . . . . . 3–27
Flywheel Face Alignment, check (632) . . . . . . . . . 7C–10 Hydrostatic Motors, removing the (630 & 632
Flywheel, installation of (630) . . . . . . . . . . . . . . . . . 7A–13 S/N 15320 & Below) . . . . . . . . . . . . . . . . . . . . . . . . . 3–26
Flywheel, removal of (630) . . . . . . . . . . . . . . . . . . . . . 7A–6 Hydrostatic Motor, repair (630 & 632
Flywheel Ring Gear (632) . . . . . . . . . . . . . . . . . . . . 7C–25 S/N 15320 & Below) . . . . . . . . . . . . . . . . . . . . . . . . . 3–30
Fuel & Control Linkage Adjustment, F2L411D (631) 7B–3 Hydrostatic Motor, repair (631 & 632
Fuel Delivery, adjustment of F2L411D (631) . . . . . . 7B–6 S/N 15321 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . 3–36
Fuel Delivery, adjustment of F2L511D (631) . . . . . 7B–25 Hydrostatic Motor, start–up procedure . . . . . . . . . . . 3–35
Fuel Filter, F2L411D (631) . . . . . . . . . . . . . . . . . . . . . 7B–4 Hydrostatic Pump Assembly, repair . . . . . . . . . . . . . 3–19
Fuel Filter, F2L511D (631) . . . . . . . . . . . . . . . . . . . . 7B–22 Hydrostatic Pump Disassembly . . . . . . . . . . . . . . . . 3–19
Fuel Injection Nozzles, F2L411D . . . . . . . . . . . . . . . 7B–7 Hydrostatic Pump Inspection . . . . . . . . . . . . . . . . . . . 3–20
Fuel Injector Nozzles, F2L511D (631) . . . . . . . . . . 7B–26 Hydrostatic System, to remove air from . . . . . . . . . 3–29
Fuel Injection Nozzles, disassembly & repair
F2L411D (631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–7 Idler Gear & Shaft, installation of (630) . . . . . . . . . 7A–12
Fuel Injection Nozzles, installation of F2L411D (631)7B–7 Idler Gear & Shaft, removal of (630) . . . . . . . . . . . . 7A–7
Fuel Injection Nozzles, removal of F2L411D (631) 7B–7 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–14
Fuel Injection Pump, F2L411D (631) . . . . . . . . . . . . 7B–5 Ignition System (632) . . . . . . . . . . . . . . . . . . . . . . . . . 7C–6
Fuel Injection Pump, F2L511D (631) . . . . . . . . . . . 7B–23 Ignition System Tests (632) . . . . . . . . . . . . . . . . . . . . 7C–7
Fuel Injection Pump, removal of F2L511D (631) . . 7B–5 Ignition Timing (632) . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–8
Fuel Injection, removal of F2L511D (631) . . . . . . . 7B–23 Inspecting, 30–hour . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Fuel Injection Pump Service, F2L411D (631) . . . . . 7B–5 Inspection, pre–delivery . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Fuel Injection Pump Service F2L511D (631) . . . . 7B–23 Intake Manifold (632) . . . . . . . . . . . . . . . . . . . . . . . 7C–18
Fuel Injection Pump, to install F2L411D (631) . . . . 7B–5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Fuel Injection Pump, to install F2L511D (631) . . . 7B–23
Fuel Lift Pump, F2L411D . . . . . . . . . . . . . . . . . . . . . . 7B–4 Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Fuel Lift Pump, F2L511D . . . . . . . . . . . . . . . . . . . . . 7B–23 Lift Arms, pivot pin replacement . . . . . . . . . . . . . . . . . 5–1
Fuel Shut–Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 Lift Cylinder, checking . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
Fuel System (630, 632) . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 Lubrication, loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16
Fuel System, F2L411D (631) . . . . . . . . . . . . . . . . . . . 7B–3
Fuel System, F2L511D (631) . . . . . . . . . . . . . . . . . . 7B–21 Main Frame To Upright Frame Bolts . . . . . . . . . . . . . 5–3
Fuel System (General) (631) . . . . . . . . . . . . . . . . . . . . . 1–9
Fuel System, venting air from, F2L411D (631) . . . . 7B–3 Oil Cooler, engine F2L511D (631) . . . . . . . . . . . . . 7B–40
Fuel System, venting air from, F2L511D (631) . . . 7B–22 Oil Pan (632) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–25
Oil Pan, installation (630) . . . . . . . . . . . . . . . . . . . . . . 7A–9
Gear Cover, installation of (630) . . . . . . . . . . . . . . . 7A–12 Oil Pan, removal of (630) . . . . . . . . . . . . . . . . . . . . . . 7A–7
Gear Cover, removal of (630) . . . . . . . . . . . . . . . . . . 7A–6 Oil Pump (632) . . . . . . . . . . . . . . . . . . . . . . 7C–16, 7C–26
Governor Adjustment (630) . . . . . . . . . . . . . . . . . . . . 7A–5 Oil Pump, Filter Housing & Relief Valve
Governor, F2L411D (631) . . . . . . . . . . . . . . . . . . . . 7B–16 F2L411D (631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–13
Governor, F2L511D (631) . . . . . . . . . . . . . . . . . . . . 7B–37 Oil Pump, Filter Housing & Relief Valve
Governor Service (630) . . . . . . . . . . . . . . . . . . . . . . 7A–13 F2L511D (631) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–34
Oil Pump, installation of (632) . . . . . . . . . . . . . . . . . 7A–11
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7 Oil Pump, removal of (630) . . . . . . . . . . . . . . . . . . . . 7A–7
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 Oil Seal Crankshaft Rear (632) . . . . . . . . . . . . . . . 7C–26
Hydraulic Cylinder, removing . . . . . . . . . . . . . . . . . . . . 2–12 Oil Seal, front (632) . . . . . . . . . . . . . . . . . . . . . . . . . 7C–23
Hydraulic Cylinder, repair . . . . . . . . . . . . . . . . . . . . . . . 2–13
Hydraulic Fluid & Filter . . . . . . . . . . . . . . . . . . . . . . . . . 1–14 Pistons & Connecting Rods (632) . . . . . . . . . . . . . 7C–27
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 Pistons & Connecting Rods, installation of (630) . 7A–10
Hydraulic Pump Replacement . . . . . . . . . . . . . . . . . . . 2–11 Pistons & Connecting Rods, removal of (630) . . . . 7A–7
Hydraulic System Information . . . . . . . . . . . . . . . . . . . . 2–7 Pistons, Pins & Rings (632) . . . . . . . . . . . . . . . . . . 7C–12
Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13 Piston Rings, installation of (630) . . . . . . . . . . . . . . 7A–10
Hydrostatic Motors (630&632S/N15320& Below) . . 3–26 Pump Assembly, #1 . . . . . . . . . . . . . . . . . . . . . . . . . . 3–24
Hydrostatic Motor Assembly (630 & 632 Pump Assembly, #2 . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23
S/N 15320 & Below) . . . . . . . . . . . . . . . . . . . . . . . . . . 3–32 Pump Assembly, removal & installation . . . . . . . . . . 3–18
Hydrostatic Motor Assembly (631 & 632 Pumps To Manifold Block, installing . . . . . . . . . . . . . 3–25
S/N 15321 & Above . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38
Hydrostatic Motor Disassembly (630 & 632 Quick–Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–17
S/N 15321 & Above . . . . . . . . . . . . . . . . . . . . . . . . . . 3–36 Quick–Couplers, restriction in the . . . . . . . . . . . . . . . 2–17
Hydrostatic Motor Disassembly & Inspection
(630 & 632 S/N 15320 & Below) . . . . . . . . . . . . . . . . 3–31 Rectifier, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–25
274 of 284
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9 ALPHABETICAL INDEX (Cont’d)
Rectifier Module, to check the . . . . . . . . . . . . . . . . . . . 6–21 Valve Rocker Arm (632) . . . . . . . . . . . . . . . . . . . . . 7C–17
Regulator, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–24 Valve & Seat Inserts, removal of (630) . . . . . . . . . . 7A–8
Regulator Module, to check the . . . . . . . . . . . . . . . . . 6–21 Valve Seat, grinding (632) . . . . . . . . . . . . . . . . . . . . 7C–11
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10 Valves & Seat Inserts, installation of (632) . . . . . . 7A–10
Relief Valve, oil pressure F2L411D (631) . . . . . . . 7B–14 Valve Spring (632) . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–20
Relief Valve, oil pressure F2L511D (631) . . . . . . . 7B–34 Valve Tappets, installation of (632) . . . . . . . . . . . . . . 7A–9
Replenishing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17 Valve Tappets, removal of (632) . . . . . . . . . . . . . . . . 7A–9
Replenishing Valves, checking . . . . . . . . . . . . . . . . . . 3–17
ROPS, removal & installation . . . . . . . . . . . . . . . . . . . . 5–1 Water Pump (632) . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–21
Rotor, checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–25
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
630, 631, 632 Loader

276 of 284
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630–1
® Revision Number
18 August 1983
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT X
SERVICE MANAGER
Model 630, 631, 632 SALES MANAGER
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.
277 of 284 –5
278 of 284
–4
630–2
® Revision Number
31 January 1985
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 630 SERIES SALES MANAGER
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 3–45 Revised Jan. 85
3–46 Added Aug. 83 3–46 Added Aug. 83
Printed in U.S.A.
279 of 284 –3
280 of 284
–2
630–3
® Revision Number
31 March 1985
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Model 630, 631, 632 SALES MANAGER
Manual No. 6556454 (4–81)–2M

TAKE OUT PUT IN
2–7, 2–8 2–7 (Revised Mar. 85), 2–8
3–19, 3–20 3–19 (Revised Mar. 85), 3–20
3–25, 3–26 3–25 (Revised Mar. 85), 3–26 (Revised Mar. 85)
3–31, 3–32 3–31, 3–32 (Revised Mar. 85)
3–33, 3–34 3–33, 3–34 (Revised Mar. 85)
3–35, 3–36 (Revised Aug. 83) 3–35 (Revised Mar. 85), 3–36 (Revised Aug. 83)
3–37 (Revised Aug. 83, 3–38 (Revised Aug. 83) 3–37 (Revised Mar. 85), 3–38 (Revised Aug. 83)
6–19, 6–20 6–19, 6–20 (Revised Mar. 85)
6–21, 6–22 6–21 (Revised Mar. 85), 6–22
7B–15, 7B–16 7B–15 (Revised Mar. 85), 7B–16
7B–17, 7B–18 7B–17, 7B–18 (Revised Mar. 85)
7B–37, 7B–38 7B–37, 7B–38 (Revised Mar. 85)
7B–39, 7B–40 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–1 (Revised Mar. 85), 8B–2 (Revised Mar. 85)
8B–7 8B–7 (Revised Mar. 85)
8C–1, 8C–2 8C–1 (Revised Mar. 85), 8C–2 (Revised Mar. 85)
8C–3, 8C–4 8C–3 (Revised Mar. 85), 8C–4 (Revised Mar. 85)
8C–5, 8C–6 8C–5 (Revised Mar. 85), 7C–6
8D–1, 8D–2 8D–1 (Revised Mar. 85), 8D–2
Printed in U.S.A.
281 of 284 –1
282 of 284
0
630–4
® Revision Number
22 March 1988
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Model 630 SERIES SALES MANAGER
Manual No. 6556454 (4–81)–2M
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.
283 of 284 i
284 of 284
ii

SM-Bobcat 630, 631, 632 Skid Steer Loader Service Repair Manual PDF

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2 of 284

Dealer Copy -- Not for Resale

CORRECT CORRECT CORRECT

B-10731a B-12365 B-7469

Dealer Copy -- Not for Resale

B-6590 B-6580 B-6589

3. Lubricate the machine.

4. Check battery condition and cables. DRIVE

6. Check electrical charging system.

Dealer Copy -- Not for Resale

12. Operate the loader, checking all functions.

630, 631, 632 Loader

630, 631, 632 Loader

Dealer Copy -- Not for Resale

630, 631, 632 Loader

630, 631, 632 Loader

Dealer Copy -- Not for Resale

1–1.2 Serial Number Identification

630, 631, 632 Loader

Dealer Copy -- Not for Resale

2. To correct wrong maintenance

3. For demonstration of correct

630, 631, 632 Loader

SERVICE SCHEDULE HOURS

ITEM SERVICE REQUIRED

Dealer Copy -- Not for Resale

630, 631, 632 Loader

In some conditions the rear door can be

Dealer Copy -- Not for Resale

630, 631, 632 Loader

Dealer Copy -- Not for Resale

Oil Fill Cap

Oil Drain Cap C–02299

630, 631, 632 Loader

SAE 20W–20 Minimum

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE Maximum B–02663

Dealer Copy -- Not for Resale

1. Stop the engine. Crankcase

3. Remove the engine oil.

6. Clean area around filter base.

630, 631, 632 Loader

NOTE: Be sure (1) gasket surfaces

Dealer Copy -- Not for Resale

3. Inspect complete air cleaner Gasket

c. If the engine does not stop,

630, 631, 632 Loader

Stop and cool the engine before

4. Use only clean fuel.

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

Dealer Copy -- Not for Resale

1. Turn fuel valve off (Fig. 1–21). Fuel

630, 631, 632 Loader

1–3.4a Fuel System (631)

Dealer Copy -- Not for Resale

630: Carburetor Adjustment (Fig. Throttle

1. Turn needle all the way in. DO

2. Turn needle out

2. Hold governor speed change lever against the stop.

Dealer Copy -- Not for Resale

1/2’’ (13 mm)

630, 631, 632 Loader

Removing Coolant From System

2. Remove temperature sender B–02661