Service Manual: Includes H Series

6 6
0 0
0 3
0
D
INCLUDES
H SERIES
Service
6 6 Manual
Dealer Copy -- Not for Resale

1 1
0 1
6556276 (6–87) Printed in U.S.A. © Melroe Company 1987
1 of 214
2 of 214
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

Lift Arm
Support
Device
B-10731a B-1537 B-7469
Never service the Bobcat Skid-Steer Use the correct procedure to lift or Cleaning and maintenance are
Loader without instructions. lower operator cab. Always use an required daily.
approved lift arm support device to
hold lift arms in raised position.
WRONG WRONG WRONG

B-11799 B-15231 B-15280
Have good ventilation when Disconnecting or loosening any Never work on loader with lift arms
welding or grinding painted parts. hydraulic tubeline, hose, fitting, up unless lift arms are held by a lift
Wear dust mask when grinding component or a part failure can arm support device.
painted parts. Toxic dust and gas cause lift arms to drop. Do not go Never modify equipment or add
can be produced. under lift arms when raised unless attachments not approved by
Avoid exhaust fume leaks which supported by an approved lift arm Bobcat Company.
can kill without warning. Exhaust support device. Replace it if
system must be tightly sealed. damaged.
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, electrical flammable and explosive gases.
checking fluids. contact, hot parts and exhaust. Keep arcs, sparks, flames and
Never service or adjust loader with Wear eye protection to guard from lighted tobacco away from
the engine running unless battery acid, compressed springs, batteries.
instructed to do so in the manual. fluids under pressure and flying Batteries contain acid which burns
Avoid contact with leaking debris when engines are running eyes or skin on contact. Wear
hydraulic fluid or diesel fuel under or tools are used. Use eye protective clothing. If acid contacts
pressure. It can penetrate the skin protection approved for type of body, flush well with water. For eye
or eyes. welding. contact flush well and get
Never fill fuel tank with engine Keep rear door closed except for immediate medical 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.
MSW05-0805
3 of 214
4 of 214
FOREWORD GENERAL
SERVICE
This manual provides instruction for proper routine servicing and adjustment of the Bobcat, and
detailed overhaul instructions of the power train, loader hydraulic/hydrostatic system and
general mainframe components.
Refer to the Owner’s Manual for general operating instructions (Starting Procedure, Daily TROUBLE–
Check, Bucket Operation, Minor Maintenance, etc.).
SHOOTING
A general inspection of the following items should be made whenever the machine has
undergone service or repair:
1. Check hydraulic fluid level, engine oil level and fuel supply. DRIVE
SYSTEM
2. Inspect for any sign of fuel, oil or hydraulic fluid leaks.
3. Lubricate the machine.
4. Check battery condition, electrolyte level and cables. HYDRAULIC

SYSTEM
5. Inspect air cleaner system for damage or leaks. Check element and make replacement,
if necessary.
6. Check alternator drive belt for condition and tension.

WISCONSIN
7. Check for loose drive chains by lifting the rear of the machine and turning the rear wheels ENGINE SERVICE

by hand.
8. Check tires for wear and pressure.
9. Check the Bob–Tach attachment for condition. Inspect the wedges for damage or wear. DEUTZ ENGINE
SERVICE
10. Inspect safety items for condition (ROPS Guard, Seat Belt, Safety Treads, Lights, etc.).
11. Make a visual inspection for loose or broken parts or connections.
12. Operate the loader, checking all functions. PETTER ENGINE

SERVICE
Advise the owner if any of the above items are in need of repair.
CONTENTS SPECIFICATIONS
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1

DEUTZ ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 ALPHABETICAL
GENERAL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 INDEX
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
PETTER ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
WISCONSIN ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
600, 600D, 610, 611 Loader

5 of 214 –1––3– Service Manual
600, 600D, 610, 611 Loader

GENERAL SERVICE
GENERAL
Paragraph Page SERVICE
Number Number
CHANGING AND ADDING HYDRAULIC OIL . . . . . . . . . . . . . 1–3 1–2
CRANKCASE AIR VENT (DEUTZ) . . . . . . . . . . . . . . . . . . . . . . 1–15 1–7
CRANKCASE AIR VENT (WISCONSIN) . . . . . . . . . . . . . . . . . 1–14 1–7
DISTRIBUTOR MAINTENANCE (WISCONSIN) . . . . . . . . . . . 1–22 1–10
ENGINE AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 1–4
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19 1–8
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 1–5
ENGINE OIL FILTER (DEUTZ) . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 1–6
ENGINE OIL FILTER (WISCONSIN) . . . . . . . . . . . . . . . . . . . . . 1–11 1–6
FUEL ADJUSTMENT (PETTER) . . . . . . . . . . . . . . . . . . . . . . . . 1–18 1–8
FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 1–7
FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–16 1–7
HEAVY DUTY AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 1–4
HYDRAULIC FLUID FILTER CHANGE . . . . . . . . . . . . . . . . . . . 1–5 1–3
IGNITION TIMING (WISCONSIN ENGINE) . . . . . . . . . . . . . . . 1–21 1–9
LOADER LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 1–2
OIL FILTER (PETTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 1–6
OIL SPECIFICATIONS FOR ENGINES . . . . . . . . . . . . . . . . . . 1–10 1–5
OIL TYPE AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 1–4
REMOVING WATER FROM HYDRAULIC TANKS . . . . . . . . . 1–4 1–2

SPARK PLUG (WISCONSIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23 1–10
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 1–2
WATER SCRUBBER MUFFLER (600 DIESEL) . . . . . . . . . . . 1–20 1–8
600, 600D, 610, 611 Loader

600, 600D, 610, 611 Loader

8 of 214 –1–0– Service Manual
SERVICE SCHEDULE HOURS
80–100
40–50
8–10
1000
2000
200
300
500
MODEL ITEM SERVICE REQUIRED
G,D,P,E All Loader Pivots Grease fittings (10) until excess shows.
G,D,P Engine Air Cleaner (Dry Type) Clean cup as necessary. Change cartridge only when indicator
show red ring.
D Oil Bath Air Cleaner Check condition of oil
G,D,P Engine Oil Add to full mark. Do not overfill. Use correct oil for engine.
G,D,P * Engine Air Inlet Screen Check and clean as necessary.
G,D,P Cooling Fins & Shroud Backflush with air as necessary.
G,D,P Starting Motor Flush with air as necessary.
E Cable Swivel Put grease in fittings (2) until it shows.
G,D,P,E Variable Sheaves Put grease in fittings (2); drive and driven sheave.
G,D,P,E Control Levers & Pedals Put grease in fittings (7) until it shows.
G,D,P Engine Oil Make replacement. Refer to Engine Manual.
G,D,P Engine Oil Filter Make replacement of element.
G Distributor Cam (Wisconsin) Put drop of oil in spring cap oil cup.
G,D,P,E** Final Drive Chains Make adjustment as necessary.
D Oil Bath Air Cleaner (Bureau of Clean and refill with engine oil.
Mines)
G,D,P Engine Air Cleaner (Dry Type) Check operation of condition indicator.
G,D,P,E Hydraulic Oil Filter Make replacement at 100 hours.
G,D,P Crankcase Breather Inspect. Service as necessary.
G,D,P,E Steering Clutches Make adjustment when lever travel exceeds 3–4 inches from

neutral in either direction (fully engaged).
D Engine Valve Tappets Check clearance. Make adjustment if necessary.
G Plugs & Points Clean. Gap install new as necessary. Tighten spark plugs.
G Generator (M–444) Add lubricant.
D Engine Fuel Filter Clean or install new element.
D Engine Blower V–Belt Tension Check. Make adjustment as necessary.
P Engine Valve Tappets Check clearance. Make adjustment if necessary.
G Engine Cylinder If over 90 PSI compression remove carbon from combustion
chambers.
G,D,P Engine Shroud Remove to clean engine cooling fins.
G,D,P,E Drive Belt & Sheaves Check for tension, alignment and wear.
G,D,P Starting Motor Remove, clean and service.
G Engine Remove head. Clean carbon from combustion chambers.
Make adjustment of valves if necessary.
D Crankshaft Breather Clean copper mesh element.
G,P,D,P Hydraulic, Transmission Sump Remove condensation. Check level. Add as necessary.
P Engine Fuel Filter Clean or install new element.
P Oil Pump Strainer Clean.
P Engine Cylinders Remove carbon from combustion chambers.
E Motor Bearings Add lubricant. For interval, follow instructions plate on motor.
G,D,P,E Hydraulic, Transmission Sump Make replacement of oil. Approximately 18 gallons are needed.
Model Code: G, Gasoline & LP Gas; D, Deutz Diesel; P, Petter Diesel; E, Electric
* On fertilizer, grain or other extremely dusty operations, clean more often as required.
** Adjust after first 50 hours of operation. Check daily if solid type tires are used.
600, 600D, 610, 611 Loader

Revised February 80
GENERAL SERVICE
1–1 TIRES
Tire air pressure on standard 7:00 x 15,6 ply should be 55 PSI (379 kPa). Flotation
tire air pressure should be 25 PSI (172 kPa). Air pressure must be the same in all
tires for longer life.
Tires can be filled with calcium chloride for more load stability and traction. They
must not be filled to more than 80% of capacity of tire.
NOTE: Flotation tires should not be filled with calcium chloride except in
pulpwood operation.
A–01250
Tire rotation should be done when 1/8
inch (3,2 mm) difference is found in Fig. 1–1 Tire Rotation
wear of tire (Fig 1–1).
When putting new tire on loader, check
that size is the same as other tires on
loader.
1–2 LOADER LUBRICATION

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

1–1) for correct time intervals.
1–3 CHANGING AND ADDING

HYDRAULIC OIL
The loader holds 18 gallons of hydraulic
oil which need not be changed unless
loader is run under very dirty conditions
for a long period of time. Otherwise
change oil every 1000 hours or if oil has
become dirty or white in color.
Check oil level every 50 hours of
operation, on a level surface. When low
add approved oil and fill to the upper
check plug (Fig. 1–3).
1–4 REMOVING WATER FROM
HYDRAULIC TANKS VARIABLE SPEED DRIVEN
SHEAVE ADJUSTMENT
Water should be removed every 1000 EXCEPT ON M–600 MODEL
hours of operation or more often if PI–01033 PI–01027
loader is operated in a climate where Fig. 1–2 Loader Lubrication
much water is present in the air.
To remove water from the reservoir:
1. Use tilt control to raise front

wheels of the loader several
inches off of the ground.
2. Allow the loader to stand for 3–4

hours.
3. Remove drain plug (Fig. 1–3) for

water to run off .
Check Plugs
Drain Plug B–01507
Fig. 1–3 Reservoir Check and Drain Plugs
600, 600D, 610, 611 Loader

1–4a BOB–TACH FRAME
Check Bob–Tach and weld areas as
necessary (Fig. 1–3a).
1–5 HYDRAULIC FLUID FILTER

CHANGE
See SERVICE SCHEDULE Page 1–1
for time interval.
1. Lower lift arms. Lift from of the

loader 5–6 inches (127–152 mm)
on 600 Electric and Petter diesel.
Lift rear of machine 5–6 inches on
600, 610 and Deutz diesel. This A–02533
will prevent oil from running out Fig. 1–3a Weld Areas
when filter is removed.
2. Remove floor panels and

disconnect linkage (600 Electric
and Petter diesel).

3. Remove seat and engine cover
(600, 610 and Deutz 610). Element
Spring
4. Remove element, seals and
spring from housing (Fig. 1–4).
5. Remove seal from center shaft

(Fig. 1–4, Item 1).
6. Clean parts in a cleaning fluid and

dry. Seals
2
7. Assemble new filter (Fig. 1–4).
1
8. Check housing seal (Fig. 1–4,
Item 2). C–01244
Fig. 1–4 Hydraulic Fluid Filter Assembly
9. Install filter assembly to loader
and tighten nut to 12 ft.–lbs. (83
kPa) (Fig. 1–5).
10. Lower the loader and run engine at

idle until hydraulics work
smoothly. Fill Port
11. Check for leaks and check level of

fluid. It should need 2 quarts (1.9
ltr.) for filter element. Fill to the
upper check plug (Fig. 1–6).
Check Ports
Drain Port
C–01785 PI–01019
Fig. 1–5 Installing Filter Assembly Fig. 1–6 Hydraulic fluid Level Check
600, 600D, 610, 611 Loader

11 of 214
Revised February 80 –1–3– Service Manual
1–6 ENGINE AIR CLEANER
1. See SERVICE SCHEDULE (Page

1–1) for intervals.
2. Clean all foreign material from

outside of housing.
3. Remove old element (Fig. 1–7).
4. Install new element (Fig. 1–7).
5. Set indicator ring back to normal

(Fig. 1–8).
6. Inspect air cleaner for leaks:

a. Dust cap holder
C–01024
b. Filter gasket
Fig. 1–7 Air Cleaner Assembly
c. Dust cap
d. Dust cap sealing edge
e. Filter leaks Reset Button

f. Hose and connections.
g. Check system by removing dust
cover and hold hand over inlet
with engine running at idle to 1/4
throttle. Engine should stop (Fig.
1–11). Reset indicator and install
dust cover.
1–7 OIL TYPE AIR CLEANER

1. Stop loader and let stand for one
hour.
2. Remove bottom cup and clean.

A–01600 Cup
3. Fill cup with oil to correct level (Fig. Fig. 1–8 Condition Indicator Fig. 1–9 Oil Bath Air Cleaner
1–9).
4. Install cup.
1–8 HEAVY DUTY AIR CLEANER
1. An indicator located on front of air
cleaner indicates condition of filter
(Fig. 1–10).
2. When red ring is in window,

remove element and install new
element (Fig. 1–10).
NOTE: Do not clean or install old
element.
3. Inspect hoses and connection for Indicator

leaks.
4. Inspect and clean vanes on air

cleaner (Fig. 1–10).
C–01088 A–01600
Fig. 1–10 Heavy Duty Air Cleaner Fig. 1–11 Checking System
600, 600D, 610, 611 Loader

12 of 214 80
Revised February –1–4– Service Manual
1–9 ENGINE OIL
1. Check SERVICE SCHEDULE on page 1–1 for time interval.
2. Empty oil when engine is warmed up.
3. Capacity of oil for engine follows:

Wisconsin=7 pints (3,3 L)+1 pint (,5 L) when filter is changed.
Deutz=4–1/2 quarts (4,2 L) with filter.
Petter=5–1/2 quarts (5,1 L) with filter.
1–10 OIL SPECIFICATIONS FOR ENGINES

Replace the engine oil and filter every 50 hours of loader operation.
RECOMMENDED SAE VISCOSITY NUMBER

(LUBRICATION OILS FOR ENGINE CRANKCASE)
C°–34 –29 –23 –18 –13 –7 –1 +4 +10 +15 +21 +27 +32 +38 +43 +49 +54 +60

SAE 10W–30
SAE 15W–40
SAE 5W–30
SAE 30W
SAE 20W–20
SAE 10W
⎧°–30 –20 –10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120 +130 +140
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE

(GASOLINE: USE API CLASSIFICATION SE)
(DIESEL: USE API CLASSIFICATION CD)
600, 600D, 610, 611 Loader

13 of 214
1–11 ENGINE OIL FILTER (Wisconsin)
Check SERVICE SCHEDULE Page 1–1 for time interval.
1. Remove filter element (Fig. 1–12).
2. Install new filter and hand tighten (Fig. 1–13).
3. Start engine and check for leaks.
4. Run engine at full throttle for 1 minute then stop engine.
5. Tighten filter by hand.

1–12 ENGINE OIL FILTER (Duetz Diesel – Fig. 1–13)
Change the filter element at every engine oil change. To change the filter, use this
procedure:
1. Remove and discard the oil filter cartridge. B–01832
Fig. 1–12 Remove Engine Oil Filter
2. Install a new filter cartridge, turn it on hand tight.
3. Start the engine and run it at idle for five minutes while checking for oil leaks
at the filter.

4. Run the engine at full throttle
(2400 RPM) for at least one
minute, then stop engine.
5. Tighten the cartridge again (hand

tight).
OIL FILTER (Petter)

See SERVICE SCHEDULE Page 1–1
for time interval.
1. Remove filter cover (Fig. 1–14).
2. Remove oil filter element.
3. Clean filter housing anD remove

dirt and oil.
4. Install new element and tighten

cover to 10 ft.–lbs. (13,55 Nm).
Fig. 1–13 Install Engine Oil Filter (Deutz)
NOTE: After installing oil filter on
engines, run engine and
check for leaks. Stop engine
and check oil level.
Filter Cover
Filter
WARNING
Cold weather starting (below
32°F.) with heavier than 10W
engine oil can stretch the
filter cartridge causing a leak.
Tighten the filter cartridge
after every few cold starts to
be sure it stays tight.
W–2265–0997
Fig. 1–14 Remove Filter cover (Petter)
600, 600D, 610, 611 Loader

14 of 214 80
1–14 CRANKCASE AIR VENT (Wisconsin)
610,611ServiceManual#6556276–Contents&GeneralServiceSectionPages1–7
See SERVICE SCHEDULE Page 1–1 for time interval. Inspect fittings and hoses
for leaks (Fig. 1–15).
1–15 CRANKCASE AIR VENT (Deutz)

See SERVICE SCHEDULE Page 1–1 for time interval. The vent housing contains
a copper element as a filter.
1. Remove bolts that hold crankcase vent housing in place (Fig. 1–16).
C–01569
2. Remove housing and vent tube assembly from engine (Fig. 1–17). Lay it face
up and install clean copper element. Fig. 1–15 Crankcase Air Vent (Wisconsin)
3. Install vent tube on engine. Check

that housing is correct on engine.
Seal it using an industrial cement
before tightening bolt.
NOTE: Remove vent tube from
engine every 500 hours and
wash element in cleaning
solvent.

1–16 FUEL SPECIFICATIONS
A–01601
Wisconsin engine uses regular Fig. 1–16 Crankcase Breather (Deutz) Fig. 1–17 Deutz Breather W/Element
gasoline.
Deutz engine uses a number 2 diesel fuel for temperatures above 30°F.
Element
Petter engine uses number 2 diesel fuel.
1–17 FUEL FILTER

L.P. Gas: A filter with an ignition switch actuated shut–off lock is located
(WIsconsin) between the inlet hose and vaporizer. This must be serviced
regularly. Remove the old element and install new element
when servicing (Fig. 1–18).
Deutz: Remove fuel filter and install new filter every 200 hours (Fig.
1–19). Air removal from fuel lines is necessary after filter service. B–01171
Fig. 1–18 LP Gas Fuel Filter
Petter: Remove fuel filter and
install new filter every
1000 hours (Fig.
1–20). Air removal
from fuel line is
necessary after filter
service.
Wisconsin: Remove in–line filter

(Deutz) every 200 hours.
Check condition by
blowing through
element, in same
direction as arrow.
Make replacement of
dirty element. A–01592 A–01591
Fig. 1–19 Deutz Fuel Filter Fig. 1–20 Petter Fuel Filter
600, 600D, 610, 611 Loader

610 Loader
1–17a EXCESS FUEL LEVER ADJUSTMENT (Deutz Engine)
610,611ServiceManual#6556276–Contents&GeneralServiceSectionPage7a
Engine does not start because excess fuel lever does not operate correctly. The
excess fuel button must be pushed fully down, when the throttle lever is pulled all
the way backward while stopping the engine, this is done through movement of
the excess fuel lever (Fig. 1–20a).
Check the operation of the lever by pulling the throttle lever fully backward. While
the throttle is held in this position check to see if the excess fuel button is pushed
down by the adjustment bolt (Fig. 1–20b, Item 1). Make an adjustment of the bolt
if necessary to fully push the excess fuel button down. Install a longer bolt if no
more adjustment can be made.
A–02468
Fig. 1–20a Excess Fuel Button
If necessary make additional adjustment by bending the cam plate end of the
excess fuel lever (Fig. 1–20a, Item 2) down. (Do not bend the plate so much as
to prevent full movement of the fuel rack lever (Fig. 1–20a, Item 3).
After adjustment is made check the operation by pulling throttle lever all the way 1
backward as in stopping the engine. Then move throttle forward to the 1/2 throttle
position. Check the excess fuel button. It must continue to be in the down position
for starting the engine. If the button is not down, more adjustment of the excess 2
fuel lever is necessary.

1–17b FUEL PUMP (Wisconsin) 3
A–02467
If fuel pump pressure is too high the engine will get too much fuel. Check fuel pump
pressure by installing a tee in the fuel line between fuel pump and carburetor and Fig. 1–20b Excess Fuel Lever
connecting a gauge to the tee. Run the engine at full RPM. Correct pressure is 2–3 Adjustment
PSI. If pressure is too high, install new spring from fuel pump repair kit. (See Parts
Manual.)
NOTE: Too low pressure will cause vaporlock.
Make adjustment of float level to 1–5/32 inch (28,58 mm).
600, 600D, 610, 611 Loader

17 ofFebruary
Added 214 80 –1–7a– Service Manual
1–18 FUEL ADJUSTMENT (Petter) RIGHT SIDE OF MACHINE
Inspection
1. Stop engine. Plate
8–3/8’’
2. Remove cover plug (Fig–1–21). Drill 1’’ Dia. Hole
Where Areas Cross.
NOTE: When loader is not equipped
with a hole in loader side wall 12–1/4’’
at fuel adjustment screw
location see Fig. 1–21 for
hole drilling instructions.
The hole will make fuel Drain
adjusting easier. Plug
3. Put a screw driver into hole Fig. 1–21 Locating Fuel Adjustment Hole (Petter)
(Fig.1–21). Turn in to reduce fuel
supply. turn out to increase fuel
supply.
4. Install plug. Start engine and

check its operation. Set for a
maximum power and minimum
smoke.
1–19 ENGINE COOLING SYSTEM
1. All air cooled engines must have

proper air circulation to cool well.
2. Keep blower fan and screen clear Cooling

of foreign material and housing Fins
A–01071 A–02496
free of leaks and dents.
Fig. 1–22 Deutz Cooling Fan Fig. 1–23 Clean Cooling Fins (Petter)
3. Remove housing and clean
cooling fins when need (Fig. 1–22,
1–23, & 1–24).
Never run the engine with holes in

WARNING cooling housing or with any part of
cooling housing removed.
W–2266–0997
1–20 WATER SCRUBBER MUFFLER (600 Diesel)

The following applies to United States Bureau of Mines approved model 600
equipped with an exhaust gas conditioner (Water Scrubber Muffler). B–02417
Fig. 1–24 Cleaning Cooling Fins (Wisc.)
1. Exhaust pipe and connections from engine to exhaust gas conditioner must
be kept tight and free from leaks at all times.
2. Empty scrubber at bottom outlet with engine running, after each shift (10 Level
hours). Check
Valve
3. Fill with clean water until water level reaches level check valve located on
front of scrubber (Fig.1–25).
4. Flush scrubber twice weekly by filling it with water while engine is running at
high idle. This will agitate water and any excess will be blown out with
exhaust gas.
C–01856
Fig. 1–25 Check Level Scrubber Muffler
600, 600D, 610, 611 Loader

5. Check exhaust, check valve (located between engine and exhaust gas
conditioner) (Fig. 1–26). Check each day to make sure it will open when Check
suction is applied to exhaust pipe. The check valve is intended to keep water Valve
from entering engine in event engine turns over backwards (opposite of
normal rotation).
1–21 IGNITION TIMING (Wisconsin Engine)
Find the timing notch on air screen of flywheel and make sure it is positioned in
line with the large DC letters on flywheel, behind screen (Fig. 1–27).
NOTE: Ignition point gap must be correct before timing engine.
To check timing:
C–01856
1. Connect timing light to number Fig. 1–26 Exhaust Check Valve
one spark plug.
2. Start engine and run at over 1800 Centerline Mark

RPM. Of No. 1 Cylinder
3. Point timing light so that it will

show the notch on flywheel screen VH4D
(Fig.1–28). 23°
a. VF4D engine (Model 600 Marked
VF4D Air Vane
Bobcat) is timed at 27°
before dead center. Check to On Flywheel

see that timing notch is in line
with the timing mark on
flywheel housing (Fig. 1–27,
Item 1).
b. VH4D engine (Model 610 Running Spark
Bobcat) is timed at 23° Advance timing
before dead center. Check to Mark For Checking
see that timing notch is in line With Neon Light PI–01437
with the lowe r half of the
timing hole in flywheel
housing (Fig. 1–27, Item 2).
4. To adjust timing, loosen the

distributor clamp screw and turn 1 2
the distributor body until timing is
correct (Fig. 1–29).
5. When timing is correct, tighten the

distributor clamp screw.
B–02629 B–02630
Fig. 1–27 Ignition Timing
WARNING
Engine must be running at
over 1800 RPM when making
timing adjustment. Wrong
engine timing can damage
engine.
W–2267–0997
C–01799
Fig. 1–28 Check Notch W/ Timing Light
600, 600D, 610, 611 Loaders

19 of 214
(Revised 1–78) –1–9– Service Manual
1–22 DISTRIBUTOR MAINTENANCE
(Wisconsin)
1. Turn the engine over by hand until

the breaker arm block is on a a
high point of cam (Fig. 1–29).
2. Loosen the stationary contact lock

nut and turn screw in or out until
contact gap is correct (Fig. 1–29).
3. Tighten the lock nut and check gap

(Fig. 1–29).
1–23 SPARK PLUG (Wisconsin)

The spark plug gap should be .030 inch. A–01836
Plug should be kept clean both inside Fig. 1–29 Distributor Maintenance
and out (Fig. 1–30). When insulation is
broken, install a new plug of correct heat
range. Tighten the spark plug to 25–30
ft.–lbs. (34–40 Nm) torque.

A–01825
Fig. 1–30 Spark Plug Gap
600, 600D, 610, 611 Loader

1–24 ELECTRICAL SYSTEMS
CHECKING REGULATOR AND
RECTIFIER
10–30 Ohms
NOTE: Read this completely before
attempting any checks.
VF4D Wisconsin engines have the

recifier and regulator modules mounted
to the shroud at the rear of the engine.
On some engines the rectifier and
regulator modules are behind the Ground
distributor. They are hard to check the B–01172 PI–01358
service. You may want to move the
modules out onto the shroud. To do this: Fig. 1–31 Wiring Diagram Fig. 1–32 Rectifier Check #1
1. Disconnect the connectors by

squeezing the outer ends of the
receptacles and pulling apart. Any reading
indicates a
short circuit 10–45 Ohms
2. Remove the modules from their
position behind the distributor.
3. Install the modules on the shroud

at the rear of the engine. Install the
rectifier slightly higher and to the

left of the regulator module.
NOTE: The rectifier and regulator
modules are grounded to the Ground Ground
engine frame. You will need
PI–01358 PI–01358
to remove paint from the
shroud to get a metal to Fig. 1–33 Rectifier Check #2 Fig. 1–34 Rectifier Check #3
metal contact between the
base of the modules and the
shroud. Do not install the Any reading Any reading
modules anywhere other indicates a indicates a
than on the engine. short circuit short circuit
4. Use a jumper harness (Fig. 1–31,
Item 1) to connect the stator leads
to the rectifier and regulator
modules [A]. The keyed
connectors prevent incorrect
wiring.
Examine the leads for broken wires, or
loose connections. If none are found, Ground Ground
disconnect the battery and disconnect PI–01358 PI–01358
the rectifier and regulator modules from
the jumper harness. Make sure the Fig. 1–35 Rectifier Check #4 Fig. 1–36 Regulator Check #1
bases of the modules are making good
contact with the engine shroud.
Use a ohmmeter to check for defects in Any reading Any reading
the rectifier and regulator. All the checks indicates a indicates a
can be completed without removing short circuit short circuit
anything from the machine. If a meter
connection is shown going to ground, it
means engine ground. Be sure you
have a good ground connection.
NOTE: If your ohmmeter does not

give you the readings shown
in Figures 1–32 thru 1–41,
reverse the leads going into Ground
your meter. If the readings
still differ from the readings PI–01358 PI–01358
listed, replace the part Fig. 1–37 Regulator Check #2 Fig. 1–38 Regulator Check #3
tested.
600, 600D, 610, 611 Loaders
21 of 214
(Added 1–78) –1–11– Service Manual
STATOR CHECKS Any reading Any reading
indicates a indicates a
Use a test light (or continuity tester) to short circuit short circuit
check for shorts from the stator leads to
ground. The test light will give indication
of any shorts by illuminating the bulb. If
the bulb indicating there is a short, the
stator will need show that replacement.
If the bulb does not illuminate when
checking any of the stator leads to
ground, check to make sure there is
continuous circuit, go onto the voltage
check. Use a voltmeter to check the Ground
stator. Run the engine at full RPM when
taking these readings. PI–01358 PI–01358
Fig. 1–39 Regulator Check #4 Fig. 1–40 Regulator Check #5
NOTE: The voltmeter readings can
be different from the ones
shown in Figures 1–42 thru
1–46. Use the reading given
only as a guide. 125–450 Ohms 50 Volts A.C.
If the stator is bad the readings will be a

lot different from the readings shown.
They will be lower readings.
NOTE: If the engine is not run at full

RPM the readings can be
different.
Ground
If all checks are made and all readings PI–01358 PI–01359
are acceptable, but the battery doesn’t
charge, there is probably a bad Fig. 1–41 Regulator Check #6 Fig. 1–42 Stator Check #1
connection in the wiring harness or the
battery terminal.
NOTE: The blue wire, as referred to 20 Volts A.C. 20 Volts A.C.

in these tests, is the wire next
to the red wire. It is blue
coming off the stator, but can
be any color next to the
connector.
PI–01359 PI–01359
Fig. 1–43 Stator Check #2 Fig. 1–44 Stator Check #3
140 Volts A.C. Regulator

Disconnected
20 Volts D.C.
Ground
PI–01359 PI–01359
Fig. 1–45 Stator Check #4 Fig. 1–46 Stator Check #5
600, 600D, 610, 611 Loader

(Added 1–78)
Starter
Switch LEGEND
Blk = Black
Bl = Blue
Brn = Brown
Gr = Green
Or = Orange
Pi – Pink
Pu = Purple
Rd = Red
Wh = White
Ammeter Yel = Yellow
Gauge J = Jumper
+ = Positive
– = Negative
= Ground
Oil Pressure
Indicator

Fuse
Voltage
Regulator
Alternator
Coil
Oil Pressure
Switch
Hour Meter
Switch Starter
B–01176
B–01179
C–01376
600, 600D, 610, 611 Loaders

(Added 1–78)
ALTERNATOR CHECK
The following test can be made with the
alternator in the machine. Disconnect all
wires from the alternator except the
ground wire. Connect a jumper wire
from the field connector to the battery
connector. Also connect a voltmeter
and ammeter into the circuit as shown in
the wiring diagram (Fig. 1–48).
LOAD
With the engine at full RPM and a JUMPER
carbon pile rheostat (equivalent to 25 WIRE
amp. current draw) connected across AMMETER
the battery, the alternator must give an
output of at least 14 amps (maximum GRD.
rated output is 22 amps). If the BAT.
alternator does not give at least 14
amps, it is defective and should be BATTERY
serviced at an authorized Delco–Remy
Service Center.
If the alternator charging rate is within VOLTMETER
limits, but the battery is still
undercharged or overcharged, the
following voltage regulator tests should
be made. DELCOTRON

NOTE: An overcharged battery
condition is usually
indicated by the battery
using an excessive amount PI–02269
of water, or by being hot on
top. Fig. 1–48 Alternator Check
REGULATOR CHECK #1
Use a 12 volt test light. Fasten one wire
of test light to #3 connector on the
regulator and fasten the other end to
ground. The test light must come on. If
the light does not come on, there is an
open circuit between the battery and #3
connector.
IGNITION ‘‘ON’’
REGULATOR CHECK #2 REGULATOR BLACK
Connect the voltmeter red lead

(positive) to the #2 terminal on the
regulator. Connect the voltmeter black
lead (ground) to the base of the
regulator (Fig. 1–50). The ignition RED
switch must be turned on. The voltmeter
must show 12 to 14 volts. If the
voltmeter shows a very low or zero
reading the circuit is open between #2 VOLTMETER
terminal on the regulator and the ignition
switch and the wiring must be replaced.
PI–02270
Fig. 1–49 Regulator Check #1
600, 600D, 610, 611 Loader

24 of 214
A 12 volt test light can also be used.
Connect one wire of the test light to #2
terminal on the regulator and connect
the other wire to the regulator base
(ground). With the ignition switch on, the
test light must come on. If it does not,
the circuit is open between #2 terminal
and the ignition switch. A noise will be
head whenever the #2 wire leading to
the regulator is disconnected or
reconnected. The noise is caused from IGNITION ‘‘ON’’
the contact points opening and closing.
BLACK
REGULATOR
REGULATOR CHECK #3
Disconnect the wire leading to the F
(field) terminal on the regulator.
Connect the read wire (positive) of a RED
voltmeter to the F (field) connector on
the regulator. Connect the black wire
(ground) to the regulator base (Fig.
1–51). The ignition switch must be VOLTMETER
turned on. A zero reading is an
indication that the contact closing
voltage setting is incorrect and the
regulator unit must be adjusted or

replaced.
A 12 volt test light can also be used.

Connect one wire to the F terminal on PI–02271
the regulator. Connect the other wire to
the regulator base (ground). The Fig. 1–50 Regulator Check #2
ignition switch must be on. The test light
must come on if the light does not come
on, adjust the voltage setting or replace
the regulator.
If the battery is undercharged and has

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

water because of too high a charging IGNITION ‘‘ON’’
rate, the upper contacts in the voltage
regulator are not closing soon enough. BLACK
REGULATOR
If either condition exists, have the

regulator adjusted to specifications at
an authorized Delco–Remy Service
Center.
RED
VOLTMETER
PI–02272
Fig. 1–51 Regulator Check #3
600, 600D, 610, 611 Loaders

25 of 214
Oil Pressure
Indicator LEGEND
J4 Blk = Black
Ywl J1
J3 Bl = Blue
Starter Brn = Brown
Switch Gr = Green
J2 Pu
Blk Or = Orange
Pi – Pink
Pu = Purple
Rd = Red
Rd Wh = White
J4
Gauge J = Jumper
+ = Positive
J3
Pre–Heater – = Negative
Switch = Ground
J2
Or
Oil
Pressure
J1 Switch
Hour Meter
Gauge

Fuse
Glow Plug
Indicator
Oil Pressure
Switch
Hour Meter
Switch
Voltage
Regulator
Generator
Pre–Heater
Solenoid
Starter B–01175
B–01181
C–01376
Fig. 1–52 Electrical Circuitry (Deutz W/Generator)
600, 600D, 610, 611 Loader
26 of 214
Oil Pressure
Indicator LEGEND
J1 Blk = Black
Brn Bl = Blue
BW
Starter Brn = Brown
Switch Gr = Green
J2 Wh
Or Or = Orange
J3 Pi – Pink
Pu = Purple
Rd = Red
Rd Wh = White
Blk
PW J = Jumper
Gauge
+ = Positive
1 – = Negative
Pre–Heater
Switch = Ground
J2
J3
Oil
Pressure
Pu Switch
Hour Meter
Gauge

Fuse
Glow Plug
Indicator
Oil Pressure
Switch
Resistor
Hour Meter
Switch
Alternator
Pre–Heater
Solenoid
Voltage Starter
Regulator B–01175
C–01455
C–01376
Fig. 1–53 Electrical Circuitry (Deutz W/Delco Alternators) 600, 600D, 610, 611 Loaders
27 of 214
Oil Pressure
Indicator LEGEND
J2
Blk Blk = Black
Gr J2 Bl = Blue
J1
Starter Brn = Brown
Pu
Switch Gr = Green
Or Or = Orange
Rd
Pi – Pink
Pu = Purple
Rd = Red
Yel Wh = White
Yel = Yellow
Pi Ammeter J = Jumper
Gauge + = Positive
J1 Pre–Heater – = Negative
Switch = Ground
J3
J1
Oil
Pressure
J3 Indicator
Hour Meter
Gauge

Fuse
Glow Plug
Indicator
Oil Pressure
Switch
Hour Meter
Switch
Alternator
Pre–Heater
Solenoid Starter
B–01176
B–01247
C–01376
Fig. 1–54 Electrical Circuitry (Deutz W/Lucas Alternators)
600, 600D, 610, 611 Loader
28 of 214
Starter Circuit
Switch Breaker LEGEND
Blk = Black
Pi J1 Bl = Blue
Grn
Brn = Brown
J2
Blk Gr = Green
Or = Orange
Pu Pi – Pink
Pu = Purple
Rd = Red
J1 Rd Wh = White
J2 Gauge J = Jumper
Oil + = Positive
Pressure – = Negative
Indicator = Ground
Or
Hour Meter
Gauge

Voltage
Regulator
Engine
(overheat)
Shut–Off
Switch
Alternator
Oil Pressure
Switch
Starter
B–01176
B–01180
C–01376
Fig. 1–55 Electrical Circuitry (Petter W/Delco Alternators) 600, 600D, 610, 611 Loaders
29 of 214
Oil
610,611ServiceManual#6556276–Contents&GeneralServiceSectionPages8–20
Starter
Pressure Switch LEGEND
Indicator
Blk Blk = Black
Or J1
Pi Bl = Blue
Brn = Brown
J1 Gr = Green
B1 Or = Orange
Pi – Pink
Pu = Purple
Rd = Red
Wh Wh = White
Gauge J = Jumper
+ = Positive
– = Negative
= Ground
Rd Oil
Pressure
Indicator
J1
Hour Meter
Gauge

Fuse
Oil Pressure Alternator

Switch
Starter B–01176
C–01401
C–01376
Fig. 1–56 Electrical Circuitry (Petter W/Lucas Alternators)
600, 600D, 610, 611 Loader
30 of 214
TROUBLESHOOTING
Paragraph Page
Number Number
TROUBLESHOOTING THE DRIVE SYSTEM . . . . . . . . . . . . . 2–1 2–1
TROUBLESHOOTING THE ENGINE . . . . . . . . . . . . . . . . . . . . 2–3 2–11
TROUBLESHOOTING THE HYDRAULIC SYSTEM . . . . . . . 2–2 2–5 TROUBLE–
SHOOTING
600, 600D, 610, 611 Loader

600, 600D, 610, 611 Loader

2–1 TROUBLESHOOTING THE DRIVE SYSTEM
PROBLEM CAUSE CORRECTION Ref.

Clutch will not drive or engage Clutch shafts out of adjustment. Make clutch adjustment.
correctly.
Using wrong oil. Put in correct oil.
Actuated thread hitting sidewall. Correct clutch adjustment.
Bearings are not correctly located in Bearings should be even with each
clutch plate hubs. end of hub.
Large hex nut hangs up on side cover. Change position of nut.
Clutches over tightened, no neutral on Correct clutch adjustment.
control levers.
Force needed to release clutches. No Install new actuating threads and
full thread contact between actuating nuts.
threads and actuating nuts. Threads
and nuts are worn unevenly.
Early clutch thrust bearings failure. Rough races on clutch plates. Install new bearings and races on
both clutches.
Operator putting more force than Use less force on levers.

necessary on levers.
Wrong amount of counterweight. Use correct counterweight.
SEE SECTION 3
Alignment nut not making correct Free alignment nut.
alignment.
Early clutch lining failure and wear. Rough clutch faces. Install clutch face and lining.
Clutch adjustment not correct. Install clutch lining and make
clutch adjustment.
Clutch lubrication tubelines have Inspect tubelines for restriction.

restriction.
Clutch lining has been forced on Install clutch lining and check so it
shoulder of inside clutch plate. fits loosely on shoulder of inside
clutch plate.
More than normal primary drive Upper jackshaft sprocket not in Make adjustment for correct
chain wear. alignment with outer clutch sprocket. alignment.
Chain is over tightened. Make chain adjustment.
Oil leakage of upper jackshaft Bearing in backward. Install bearing correctly.
bearings.
Bad shaft. Inspect shaft and install new shaft.
Bad seal in bearing. Install new bearing and seal.
Bad gasket for bearing housing. Tighten housing holding bolts.
Install new gasket.
Oil leakage by clutch shaft caps. Cap loose. Tighten cap.
O–ring seal installed wrong. Install new O–ring seal.
Bad O–ring seal.
600, 600D, 610, 611 Loader

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

Roto–Swivel Leak. O–ring or seal worn. Install new O–ring or seal.
Pressure higher than necessary. Make pressure adjustment.
Variable speed belt moves higher Worn O–rings in push rod of variable Install new O–rings.
than required, then goes below its speed valve.
required position.
Leaking O–rings in variable speed Make pressure adjustment.
drive.
Install new O–rings.
Stationary half sheave rough inside. Smooth and install seal kit.
Increase in direction control lever Clutch thrust bearing. Install new bearing.
movement in one direction.
Threads are bad on actuator nut. Install new actuator nut.
Splines are worn on direction control Install new lever and shaft.
lever or linkage shaft.
Direction control lever side play. Bolt is missing from direction control Install bolt.
lever.

Splines are worn on direction control Tighten the bolt.
lever or linkage shaft.
SEE SECTION 3
Holding nut is worn. Install new nut.
Loud noise in drive system. Direction control lever linkage is loose Tighten the bolt.
on lever.
Spring washers are not in place on Put spring washers in correct
actuating bar. place.
Actuating bar is bent. Straighten bar or install new bar.

Actuating nut hits bottom against side Correct clutch adjustments.
wall.
Primary chain is over tightened. Loosen and make adjustment.
Chain is out of alignment. Make correct alignment.
Upper jackshaft bearings are bad. Install new bearings.
Secondary chain is out of adjustment. Make correct adjustments.
Lower jackshaft sprocket is loose. Tighten sprocket.
Side panel is difficult to install. Self–alignment nut is not turned Turn self–alignment nut so a flat is
correctly. on top.
Secondary drive chain is over Correct adjustment on chain.
tightened.
Primary drive chain is over tightened. Correct adjustment on chain.
600, 600D, 610, 611 Loader


Lubricant fitting on variable speed Spring hits the fitting under Turn spring so it will clear fitting.
driven sheave is breaking off. compression.
Loss of power with drive belt. Belt hits bottom on drive sheave. Move lever forward to move belt
outward when placing variable
speed in low position.
Spring load jackshaft sheave not in Make sheave adjustment.
adjustment.
Grease on faces of drive and driven Clean sheaves.
sheaves.
Belt is worn. Install new belt.
Breaking of drive belt. Alignment of driven sheave. Make correct alignment.
Spring loaded sheave adjustment too Make adjustment of sheave.
tight.
Moving half of driven sheave not Clean sheave and shaft and
sliding free of shaft. lubricate.

Three sliding bolts are bearings on Install new parts.
driven sheave are worn.
Engine has come loose causing Correct alignment and inspect for
SEE SECTION 3
alignment to be off. wear.
Bore of fixed half of driven sheave is Install sheave and jackshaft.
worn.
Too high lift pressure. Correct pressure.
Chains are tight and there is free Sprocket holding nuts are loose. Tighten and lock the nuts.
play in wheels.
Worn axle splines or multiple Install new axle or sprockets.
sprockets.
Breaking of axle sprocket. Using wrong sprockets. Install correct sprockets.
Using wrong type chain. Install correct chain.
Using wrong type chain connector. Install correct chain connector.
Chain hitting other parts. Inspect chain for clearance and
correct.
Out of round sprocket. Install new sprocket.
Bushing missing on axle to hold Install bushing.
sprocket in place.
Breaking of axle. Filling bucket with front wheels off the Keep all four wheels on ground.
ground.
Wrong type chain. Install correct chain.
Wrong type chain connector. Install correct chain connector.
Wrong balanced weight. Use correct balanced weight.
Using solid tires. Reduce speed with solid tires.
600, 600D, 610, 611 Loader


Breaking drive chains. Chains are not tight enough. Tighten chains.
Worn chains and sprocket. Install new chain and sprocket.
SEE SECTION 3
Using wrong axle sprockets. Install correct sprockets.
Operating with different diameter tires Install tires with same diameter.
on same side of loader.
Using solid type tires. Install air filled tires.
Loose items in tank. Remove.
Using wrong chain. Install correct chain.
Using more counterweight than is Use correct amount of
needed. counterweight.
600, 600D, 610, 611 Loader

2–2 TROUBLESHOOTING THE HYDRAULIC SYSTEM

Hydraulic system failure. Oil level. Check hydraulic oil level and fill to
top check plug.
The hydraulic pump is not moving. Check pump coupling.
Master release valve is held open. Clean master release valve.
Clutch manifold release valve is held Remove valve and clean it.
open.
Rough hydraulic movement. Air in hydraulic system. Vent air from tubelines and
cylinders by pushing cylinders as
far as they will go in both
directions, push pedal for about 10
seconds each way.
A leak between reservoir and Check all fittings and fasteners for
hydraulic pump causes air to enter the tightness. Check that fittings on
pump. back of the vacuum gauge
(hydraulic oil filter condition
indicator) on right instrument
panel are tight.

Foreign material in clutch manifold Remove the valve and clean it.
SEE SECTION 4
release valve holds valve open so air
is pulled into the hydraulic pump
through the clutch shafts.
Dirty hydraulic oil filter is causing low Change the hydraulic oil filter
flow and high vacuum. whenever the indicator needle on
the gauge is in red zone.
The large nut on end of filter container Tighten large nut to only 12 foot
is not tightened. pounds (1.7 m/kgf).
Air is entering the hydraulic pump Install a new seal

beyond the shaft seal.
Lift arm raises slowly at full engine Lifting more than loaders rated Operate loader within rated
RPM. capacity. capacity.
There is an oil leak beyond piston Check the piston seals.
seals in one or both lift cylinders.
Lift control linkage is out of Make adjustment of linkage.
adjustment.
Leaking spool inside lift cylinder. When spool is not centered in the
valve with the pedal in neutral
position, make linkage
adjustment.
When spool or valve housing is
broken or marked, replace the
valve.
Hydraulic pump is worn and not Check condition of the pump and
delivering its rated volume of oil. repair or install new pump.
Fluid may have been used to fill the Add hydraulic oil to reservoir.
hydraulic system of a new
attachment.
600, 600D, 610, 611 Loader

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

Lift arms drift with bucket empty. Dirty check valve at the left control Clean, check valve.
valve section.
Lift control linkage is out of Make adjustments of control
adjustment. linkage so spool centers correctly
in the valve in neutral position.
Rough control valve movement. The control pedals are rough because Lubricate and clean away old
of no lubrication. grease.
The spool centering spring inside the Install new spring.
valve is broken.
The control valve housing is out of line Fasten valve group with only the
because of wrong fastening. three outside bolts, putting shims
under the valve on the bolts to
fasten it away from plate.
Loose of hydraulic fluid in hydraulic Oil may be leaking beyond any of Check all bolts and nuts for
system, (external). these seals or gaskets: looseness. Make repairs when
there is leakage beyond seals or
1. Clutch shaft caps. gaskets. Fill oil in reservoir to
make up for lost oil.

2. Gearcase side panels.
SEE SECTION 4
3. Axle.
4. Upper jackshaft. Check all seals and replace any
allowing oil loss.
5. Lower jackshaft fastenings.
6. Control lever pivots.
7. Clutch shafts fasteners.
Oil has been used to fill the hydraulic Add new hydraulic oil.
system of a new attachment.
Oil leak through hole on welded tank Check for leaks in the frame tanks
joint. and weld.
Oil is leaking beyond the lift or tilt Install shaft seals and inspect the
cylinder shaft seals. cylinder shafts for damage. Add
new oil.
Loose hydraulic connections in the Tighten the connections or install
hydraulic systems. them when they don’t seal. Add
new oil.
Oil is leaking through holes at the Remove the cylinder and weld
cylinder openings. holes. Add new oil.
Oil is leaking beyond the variable Install seals. Add new oil.
speed drive swivel seals.
Hydraulic cylinder leaks (internal). Case is damaged, causing piston to Install new cylinder.
wear flat and seal to leak oil.
Case is rough beyond the piston at Install new cylinder case and
that point. piston seals.
600, 600D, 610, 611 Loader


Hydraulic cylinder leaks (external). The shaft is rough, causing oil loss Smooth shaft. Install shaft seals.
along the shaft and bad seal. Add new oil.
There is oil line or fitting leak. Tighten or install new fitting. Add
new oil.
Hole in weld on fitting. Remove, clean the cylinder. Weld
around fitting. Add new oil.
Cylinder head leaks. Install O–ring. Add new oil.
Hole in cylinder housing. Remove the cylinder and weld.
Add new oil.
Seals are bad. Smooth rod and install seal.
Hydraulic control valve leaks The valve body is broken. Install the valve. Add new oil.
(external).
There is a hole in the valve housing. Install new valve. Add new oil.
Hydraulic control valve leaks The control linkage is out of Make adjustment of linkage so the
(internal). adjustment. spool is centered in the valve
SEE SECTION 4
housing with the control pedal in

neutral position.
The valve spool is marked. Install new valve.
The valve body is marked. Install new valve.
Lift arm does not drift down, but The load check valve will not seat Clean and install any parts
drops when raised slowly. correctly. needed.
Running the variable speed at a Do not run continuously at one
constant high variable speed position, variable speed position.
holding pressure buildup in the
cylinder can cause seal failure.
The variable speed cylinder will not The plunger in the holding release Put shims behind the cast spring
hold in high speed position (on valve part of the control valve is too holding bracket. Install .020’’ thick
models equipped with variable long. It will not allow the check ball to shims on fastening bolts. Make
speed control valve with holding seat. adjustment for release pressure of
pressure release). 600 PSI.
Worn O–rings in the plunger. Install new O–rings.
No change when the variable There is a high holding pressure Let the loader cool.
speed control lever is put in low buildup in the variable speed cylinder.
speed position (on loaders with a
check valve). Loosen the hydraulic hose fitting at
the check valve to release some of
the pressure.
Replace the variable speed control
valve with one having a pressure
release valve.
600, 600D, 610, 611 Loader


Tilt control valve body split. Casting stress due to changing shape Fasten valve group with only the
of fastening plate. three outside bolts, laying shims
under the valve on the bolts to
fasten it away from the plate.
Install new valve.
The release valve pressure is too high Lower the release setting to 1800
in lift and auxiliary valve. to 1900 PSI.
The bucket will not hold tilted back Oil leaks between the valve spool and Spool is worn or seals are bad.
with the control in neutral position. the valve housing with the spool
centered.
The lift arms drift down from raised There is an external oil leak between Check for external leaks and
position with the lift control pedal in the lift control valve and cylinders. correct.
neutral position.
The spool is not centering in the valve Make adjustment of control
housing when the control pedal is linkage so the spool will center with
released. the pedal in neutral position.
Check for a bad spool or rough
SEE SECTION 4
action.

Check for a broken spool center
spring in the valve.
Oil leaks between the valve spool and Install new valve. Check condition
the valve housing with the spool of the cylinder seals before
centering. installing the valve.
The lift cylinder seals are leaking Install new seals.
under a load.
The hydraulic oil filter condition There is a hole in the filter element. Install new filter element.
indicator shows no reading at full
engine RPM. The cork and steel gaskets have not Install new cork and steel gaskets.
been installed on the ends of filter
element during service.
The release valve in the filter Check the release valve and clean
container is holding open. it.
There is a leak in the vacuum line Check all conditions for tightness.
(between the filter and gauge).
The vacuum line (between the filter Open the line.
and gauge) is closed.
The hydraulic oil filter container has Tighten the large nut on the end of
not been tightened. the filter container to 12 ft.–lbs.
(1.7 m/kgf).
The condition indicator gauge is bad. Install new gauge.
600, 600D, 610, 611 Loader


More than normal hydraulic pump There is not enough clearance Make adjustment of adapter to
wear (600 gasoline or LP gas between the pump drive adapter hold .015 to .030 inches clearance
models). halves, over maximum thrust on the between the adapter halves.
pump drive shaft. Rotate to check for even
clearance.
Dirty hydraulic oil. Empty reservoirs and fill with clean
oil.
Pump drive out of alignment. Make correct alignment.
Noise in hydraulic pump. Oil supply is low (hydraulic oil). Fill the reservoir to the upper
check opening.
Wrong grade oil. Change to correct oil.
The oil filter is dirty. Change the oil filter.
The suction tubeline (between the Remove and clean the suction
reservoir and pump) is stopped. tubeline.
There is an air leak between the Inspect for and correct any air
SEE SECTION 4
reservoir and pump. leaks.

Worn pump coupling. Install new coupling.
The hydraulic oil is heating. Oil supply is low (hydraulic oil). Fill the reservoir to the upper
check opening.
The oil is dirty. Empty the reservoir and fill with
clean oil.
The master release valve setting is Check the pressure and set to
low. proper release setting (1700 ± 25
psi), 119.5 ± 1.8 kgf/cm@).
Lift & auxiliary relief valve set low. Set to 1800 +100 psi (126.5
+7 –0
kgf/cm@).
–0
Wrong grade oil. Empty the reservoir and change to
correct weight oil.
Worn hydraulic pump. Repair or install new pump.
Hydraulic pump seal leaks. Worn shaft seal. Install new shaft seal.
Broken body seal or gasket. Install new seal or gasket.
The bearings are out of position. Install new bearings.
There is internal wear. Install new parts.
Air in hydraulic oil. The oil supply is low. Fill the reservoir to the upper
check openings.
Air is leaking into the suction side of Inspect all fittings and fasteners
pump. and tighten.
Inspect to be sure the fittings on
back of the vacuum gauge
(hydraulic oil filter condition
indicator) on the right dash panel
are tight.
600, 600D, 610, 611 Loader


Air in hydraulic oil. (Cont’d) Air is leaking into the cushion side of Inspect to be sure all connections
pump. (Cont’d) at the hydraulic oil filter are tight.
Check for air leaking into the
hydraulic pump beyond the shaft
seals and install the seals when
leaking.
Check clutch manifold release
valve for foreign material holding
check valve open.
SEE SECTION 4
Using wrong oil. Empty release and fill to upper
check opening with correct oil.
Large amount of hydraulic pump Alignment between engine and pump Correct alignment.
coupling wear. not correct.
Auxiliary or lift control pedals will Wrong adjustment of control linkage. Make correct adjustment of
not hold in over the center position. control linkage.
Hydraulic pressure gauge Master release valve setting is low. Make adjustment of master
indicates less than 1650 (116 release valve.

kgf/cm@) with pressure control
valve open.
Master release valve is dirty. Clean valve.
Hydraulic pump worn. Install new pump.
Cartridge release setting in left and Make correct adjustment.
auxiliary control valve is low.
600, 600D, 610, 611 Loader

2–3 TROUBLESHOOTING THE ENGINE
ENGINE TYPE
CODE
D–Diesel, A–All, G–Gas
Ref.
PROBLEM CODE CAUSE CORRECTION (Section)
Engine will not turn over. A Bad fuse in the wiring. Install new fuse. 5, 6, 7
A Loose battery connection. Clean battery terminals and 5, 6, 7
connect cables, tightening them.
A Battery is discharged. Charge battery. Check charging 5, 6, 7
system.
A Bad starter switch. Install new switch. 5, 6, 7
A Loose starter connections. Tighten connections. 5, 6, 7
A Broken or disconnected wiring Connect or repair wiring harness. 5, 6, 7
harness.
Engine fails to start or is A The variable speed is in high speed. Pull variable speed drive control 5, 6, 7
difficult to start. lever all the way back before
stopping engine.

A The clutches are engaged with Make adjustment of clutches so 5, 6, 7
steering levers in neutral position. levers will travel 3 to 4 inches from
The loader will move while starting. neutral position, in each direction.
A Starting procedure is not correct. Refer to ‘‘Starting Procedure’’ in 5, 6, 7
Bobcat Operation section of this
manual.
A No fuel in tank. Put in fuel. 5, 6, 7
A The engine air cleaner is dirty. Service air cleaner. 5, 6, 7
A The air vent hole in fuel tank cap is Remove and clean cap. 5, 6, 7
plugged.
A Fuel line leaks. Repair line. 5, 6, 7
A Damaged fuel pump. Repair or install new pump. 5, 6, 7
G The carburetor is not being choked Choke as required. 5
enough.
G The carburetor is being choked too Correct choking procedures. 5
much when starting a warm engine.
A Water, dirt or foreign material in fuel. Drain and clean fuel system. Fill 5, 6, 7
with clean fuel.
G Dirty carburetor. Clean carburetor. 5
G The ignition cable is disconnected Connect ignition cable. 5
from magneto, distributor or spark
plugs.
G Broken ignition cables, cause short Repair or install new cables. 5
circuits.
600, 600D, 610, 611 Loader

2–3 TROUBLESHOOTING THE ENGINE (Cont’d)
Ref.
Engine fail to start or is G The ignition cables, distributor or Dry and clean them. 5
difficult to start (Cont’d) spark plugs are wet.
G Moisture in ignition system due to Store idle loader in a dry place as 5
fertilizer dust settling into or around far as possible from stored
switches, fuses, ignition wire, fertilizer.
battery terminals or distributor cap.
Clean fertilizer dust off loader daily 5
and wash it off frequently with
diesel fuel.
Spray ignition system with a 5
sealant made to prevent moisture
problems.
G The spark plugs are wet or dirty. Clean or install new spark plugs. 1
G the spark plug gaps are wrong. Gap or install new. 1
Engine fails to start or is G The ignition is out of time. Correct timing. 1
difficult to start.
G Bad condenser or coil. Install new. 5

G Bad distributor. Repair or install new. 5
A Wrong crankcase oil (cold weather). Use an engine oil of proper 5, 6, 7
viscosity.
A The valves are leaking or sticking. Clean and reseat the valves. 5, 6, 7
A Valve tappets out of adjustment. Make adjustment. 5, 6, 7
A Cylinders dry due to engine having Correct compression by pouring a 5, 6, 7
been out of use for some time. small amount of engine oil into
cylinders.
G Loose spark plugs. Install new gaskets and tighten. 1
A Damaged cylinder head gasket or Install new gasket and tighten. 5, 6, 7
loose cylinder head.
A Piston rings stuck in piston. Clean the parts and install new 5, 6, 7
rings.
A Damaged cylinders (lack of Repair. 5, 6, 7
compression).
D Air in the fuel system. Bleed the system. 6, 7
A Fuel filter is plugged. Install a new element. 5, 6, 7
D Faulty injector nozzle. Check, clean and make 6, 7
adjustment.
D Faulty injector pump. Make adjustment or install new 6, 7
pump.
Engine runs rough. D Wrong decompressor setting. Make adjustment. 6, 7
Power is low. Engine
may stop. D Air in fuel lines. Bleed the system. 6, 7
A Water in the fuel system. Empty fuel system. Fill with clean 5, 6, 7
fuel.
600, 600D, 610, 611 Loader

Ref.
Engine runs rough. D Air in fuel system. Check for and correct leaks. 6, 7
Power is low. Engine
may stop. D Bad injector nozzle. Check, clean and make 6, 7
adjustment.
A Fuel filter is plugged. Install a new element. 5, 6, 7
A Wrong valve clearance. Make valve adjustment. 5, 6, 7
A Broken valve spring. Install a new spring. 5, 6, 7
G Spark plug gap not correct. Correct spark plug gaps. 1
D Wrong decompressor setting. Make adjustment. 6, 7
G Wrong type spark plugs. Check recommendations. 1
G Wrong ignition timing. Correct timing. 1
G Bad spark plugs. Clean or install new. Check cause. 1
G Bad breaker points. Check for cause and install new. 1

G Loose ignition cables or worn or Repair or tighten or install new. 5
broken cables.
A Poor compression. Tighten cylinder heads and check 5, 6, 7
gaskets.
Engine fails to start or is G Incorrect fuel mixture. Make carburetor adjustment. 5
difficult to start.
G Dirty carburetor. Clean. 5
A Fuel screen fuel of foreign material. Clean. 5, 6, 7
G Carburetor flooding. Check carburetor adjustment. 5

A Governor out of adjustment. Correct adjustment. 5, 6, 7
A Sticking valves. Free the valves. 5, 6, 7
A Pitted valves. Grind or install new. 5, 6, 7
A Dirty engine (may be due to blocked Clean and clear. 5, 6, 7
exhaust.
A Wrong fuel. Drain the fuel system and fill with 5, 6, 7
clean correct fuel.
A Dirty Air cleaner. Service the air cleaner. 5, 6, 7
D Incorrect fuel timing. Make adjustment. 6, 7
A Broken compression ring. Check. Install new. 5, 6, 7
D Excessive carbon on pistons and Clean the carbon from the cylinder 6, 7
cylinder head. head and pistons.
A Worn cylinder and pistons. Recondition the engine. 5, 6, 7
600, 600D, 610, 611 Loader

Ref.
Engine overheats. A Engine is overloaded. Operate at a lower variable speed See
set. Owner’s
Manual
Operate at a 3/4 to full throttle setting.
A Engine cooling fins are dirty. Clean the cooling fins. 1
A Engine has been operated with part Clean the cooling fins and install 1
of the housing removed. housing.
A Dirty engine oil. Change engine oil. 1
D Blower not operating. Check drive. 6, 7
A using wrong grade of engine oil. Change to proper oil grade and 1
viscosity oil.
A The crankcase oil level is low. Add oil. 1
A Excessive valve clearance. Make adjustment. 5, 6, 7
D Restriction in exhaust. Remove restriction. 6, 7
A Engine is not being lubricated Check operation of engine oil pump. 5, 6, 7
properly.

D Carbon in engine. Clean the carbon from cylinder heads 6, 7
and pistons.
D Faulty injector nozzles. Check, clean and make adjustment. 6, 7
D Faulty injector pump. Make adjustment or install new. 6, 7
A Worn pistons. Install new pistons. 5, 6, 7
A Worn connecting rod bearings. Install new bearings. 5, 6, 7
D Loose flywheel. Tighten or install when bore is 6, 7
damaged.
Engine making hitting A Worn main bearings. Install new main bearings. Check 5, 6, 7
noise. proper lubrication bearings.
A Carbon on the pistons. Clean the carbon from top of pistons 5, 6, 7
and from cylinder heads.
D Fuel timing is wring. Make adjustment of timing. 6, 7
A Broken piston ring. Install a new ring or rings. 5, 6, 7
G Poor grade of gasoline. Use good grade gasoline. 1
A Engine operated under heavy load Always operate at 3/4 to full throttle –
at low speed. setting.
A Low oil supply. Add oil. 1
A Dirty oil. Change oil. 1
G Incorrect timing. Making timing adjustment. 1
G Wrong spark plugs. Install correct spark plug. 1
A Worn or loose piston pin. Install new. 5, 6, 7
A Worn main bearings. Install new. 5, 6, 7
A Excessive camshaft end clearance. Make adjustment. 5, 6, 7
600, 600D, 610, 611 Loader

Ref.
Engine will not stop. G Improper carburetor idling Make carburetor adjustment. 5
adjustment.
G Carburetor jets dirty. Clean. 5
G Spark plug gap is small. Make adjustment of gap. 1
G Leaking carburetor or manifold Tighten or install new gaskets. 5
gaskets.
G Dirty or leaking valves. Clean and reseat valves. 5
G Weak coil or condenser. Install new. 5
Oil consumption. (Light A Oil is light. Empty, refill with correct oil. 1
blue exhaust smoke.)
A Crankcase pressure. Clean vent valve. 1
A Worn piston rings. Install new. 5, 6, 7
A Crankcase overfilled. Clean vent valve. 1
Black exhaust smoke. G Fuel mixture. Make adjustment of carburetor or 5

Excessive fuel used. choke.
Spark plugs dirty.
G Choke not open. Inspect linkage and setting. 5
G Dirty air cleaner. Service the air cleaner. 1
G Crankcase pressure. Clean vent valve. 1
Low oil pressure. A Bad indicator. Install new indicator. 5, 6, 7
A Oil is light. Empty. Fill with correct oil. 1
A Oil level low. Add oil. 1

A Dirt on oil screen. Clean. 5, 6, 7
A Badly worn oil pump. Repair. 5, 6, 7
A Incorrect oil pressure setting. Make adjustment. 5, 6, 7
G Leaking fuel pump. Install new fuel pump. 5
High oil pressure. A Bad indicator. Install new indicator. 5, 6, 7
A Oil grade is heavy. Empty. Refill with correct oil. 1
A Oil lines dirty. Clean all lines and openings. 5, 6, 7
A Oil relief valve stuck. Clean by–pass. Install when 5, 6, 7
needed.
600, 600D, 610, 611 Loader

610,611ServiceManual#6556276–TroubleshootingSection
600, 600D, 610, 611 Loader

DRIVE SYSTEM
Paragraph Page
Number Number
ASSEMBLY OF BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28 3–28
ASSEMBLY OF DRIVEN SHEAVE
(STRAIGHT JACKSHAFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10 3–14
ASSEMBLY OF DRIVEN SHEAVE
(TAPERED JACKSHAFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8 3–13
ASSEMBLY OF 610 VARIABLE SPEED
W/ROTO–SWIVEL INSIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16 3–17
AXLE BEARING AND SEAL INSTALLATION . . . . . . . . . . . . . . 3–20 3–20 DRIVE
AXLE REMOVAL (FRONT AXLE) . . . . . . . . . . . . . . . . . . . . . . . 3–19 3–19 SYSTEM
AXLE SPROCKET REMOVAL INSTALLATION . . . . . . . . . . . . 3–22 3–22
BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29 3–29
BRAKE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–27 3–28
CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 3–2
DISASSEMBLY AND ASSEMBLY (CLUTCH) . . . . . . . . . . . . . 3–2 3–2
DISASSEMBLY OF DRIVEN SHEAVE
(STRAIGHT JACKSHAFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9 3–14
DRIVE BELT INSTALLATION
(SPLIT SHAFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4 3–9
DRIVE CHAIN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26 3–26
DRIVEN SHEAVE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 3–11 3–14

DRIVEN SHEAVE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 3–7 3–13
INSTALLATION OF AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–21 3–21
INSTALLATION OF DRIVEN SHEAVE . . . . . . . . . . . . . . . . . . . 3–6 3–12
INSTALLING CLUTCH NEEDLE BEARINGS . . . . . . . . . . . . . 3–3 3–9
JACKSHAFT BEARING INSTALLATION . . . . . . . . . . . . . . . . . 3–12 3–15
LOWER JACKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . 3–25 3–24
LOWER JACKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 3–23 3–23
LOWER JACKSHAFT SPROCKET REPAIR . . . . . . . . . . . . . . 3–24 3–24
REMOVAL OF DRIVEN SHEAVE . . . . . . . . . . . . . . . . . . . . . . . . 3–5 3–11
REMOVAL OF FRAME SUPPORT
VARIABLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18 3–18
REMOVAL OF VARIABLE DRIVEN SHEAVE
WITH ROTO–SWIVEL INSIDE . . . . . . . . . . . . . . . . . . . . . . . . . 3–13 3–16
REMOVAL OF VARIABLE SHEAVE
WITH ROTO–SWIVEL OUTSIDE . . . . . . . . . . . . . . . . . . . . . . 3–17 3–18
ROTO–SWIVEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15 3–17
ROTO–SWIVEL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 3–14 3–17
600, 600D, 610, 611 Loader

600, 600D, 610, 611 Loader

Driven Sheave
Assy.
Actuating
Nuts

Secondary Drive
Actuating Chain Reverse Direction
Threads Clutch Assy.
Driven Sheave
Assy.
Forward Direction
Clutch Assy.
Primary Drive
Chain
Final Drive Chain
PI–01127
Fig. 3–1 Clutch Drive System Breakdown (Right Side Shown)
600, 600D, 610, 611 Loader

SERVICE FOR DRIVE SYSTEM
610,611ServiceManual#6556276–DriveSystemSectionPages1–2
3–1 CLUTCH ADJUSTMENT

The Bobcat has two drive systems, one
on each side of the loader, each
equipped with two clutches. The front
clutch on each side of the loader is the
reverse direction clutch and the rear
clutch is the forward direction clutch
(Fig. 3–1).
PI–01026
Fig. 3–2 Clutch Adjustment
Adjustment Procedure
1. Stop the engine.
2. Use the large clutch cap wrench to

remove the caps from the clutch
shafts (Fig. 3–2, (Item 1).
3. Remove the cotter pins which hold

the castle nuts in place (Fig. 3–3).
4. Put control levers in neutral

position (Fig. 3–2).
5. Adjustment is correct for reverse B–02414 C–01779

clutch position when top of lever
can be moved 3–4 inches from Fig. 3–3 Removing Cotter Pin Fig. 3–4 O–ring In cap
neutral to full engaged reverse
6. To make correct adjustment use

small end of the clutch wrench to
tighten or loosen front castle nut
(Fig. 3–2).
7. Adjustment is correct for forward

clutch position when top of lever
can be moved 3–4 inches from
neutral to full engaged forward
8. Makes same adjustment as Step B–02023

6 & 7 to rear castle nut.
Fig. 3–5 Remove Side Cover
9. Make same adjustments to both sides of loader. Then check control levers for
even alignment in all positions (Fig. 3–2, Item 2).
10. Install cotter pin in each castle nut (Fig. 3–3).
11. Inspect quad–ring in cap and put oil on quad–ring before installing cap (Fig. 3–4).
12. Install cap and tighten (Fig. 3–2).
600, 600D, 610, 611 Loader

52 of 214
Added February 80 –3–2– Service Manual
3–1a Steering Clutch Adjustment
If steering of the loader is difficult or the

clutches do not engage correctly, check
the five items below:
Weld Nut
On Cap
1. Stop the engine and move the

steering levers. Check the side
covers to see if they have
movement. If there is movement
the cover has a bend in it. Make a A–01638 B–01545
tool for pulling the cover out by Fig. 3–5a Pulling Rool Fig. 3–5b Removing Bend in Side Panel
drilling a hole in a clutch cap and
welding a nut to it (Fig. 3–5a).
Remove the cotter key and castle
nut from clutch pin. Install the tool
(Fig. 3–5b) enough to pull the
cover out. Turned

Around
2. Remove the side cover. Turn

clutch nut around and assemble
the self–aligning race parts as
shown (Fig. 3–5c). Make an
adjustment of the steering linkage
and move the levers. If lever
action is now positive, the
self–aligning race parts have a
defect (Fig. 3–5d).
B–02278
Fig. 3–5c Reversing Clutch Nut
Metal
Particle
A–02418 A–01518
Fig. 3–5d Clutch Nut (Cross Section) Fig. 3–5e Actuating Nut (Cross Section)
600, 600D, 610, 611 Loader

53 of 214 –3–2a– Service Manual
Added February 80
3. The actuating nut, self–aligning
610,611ServiceManual#6556276–DriveSystemSectionPages2a–2b
nut, and outside clutch plates

must be checked to see if the
bearing race is in place (Fig. 3–5e,
3–5f, 3–5g). The race must be
installed so you cannot put a feeler
gauge under the race (Fig. 3–5h,
3–5i). The race must make even
contact against the clutch plate.
Make corrections as necessary.
B–02283
Fig. 3–5f Bearing Seat On Clutch Plate
4. Check the fit of the threads in the

actuating nuts. If any are loose or
have wear, install new actuating
nuts. The new actuating nuts must
be hard (Fig. 3–5j).
Feeler
Metal Gauge
Particle

5. Check the clutch plates to see that
the surfaces are flat by using a
feeler gauge. Remove the lining
from between the clutch plates
and hold the plates together by
A–01517 A–01515
hand. If there is clearance any
place on the surface of the clutch Fig. 3–5g Clutch Nut (Cross Section) Fig. 3–5h Checking Actuating Nut
plate replace the damaged clutch
plate (Fig. 3–5k).
Blue Color
From Heat
Treatment
Feeler
Gauge A–01516 A–02419
Fig. 3–5i Checking Clutch Nut Fig. 3–5j Actuating Nut
Feeler
Gauge
B–02281
Fig. 3–5k Clutch Check
600, 600D, 610, 611 Loader

54 of 214
Added February 80 –3–2b– Service Manual
3–2 DISASSEMBLY & ASSEMBLY
Disassembly
1. Remove tires and put machine on

blocks. Remove clutch caps (Fig.
3–2).
2. Remove side cover (Fig. 3–5).
B–02416 B–02415
Fig. 3–6 Remove Idler For Primary Drive Chain Fig. 3–7 Remove Castle Nut
3. Loosen the primary chain idler and
remove primary drive chain (Fig.
3–6).
4. Remove cotter pins from castle

nuts (Fig. 3–3).
5. Remove caste nut (Fig. 3–7).

6. Remove alignment nut (Fig. 3–8).
PI–01128
Fig. 3–8 Remove Alignment Nut, Race and Bearing
7. Remove thrust bearing and race
(Fig. 3–8).
8. Remove outside clutch plate (Fig.

3–9).
9. Remove clutch lining (Fig. 3–9).
10. Remove sprocket from secondary B–01946

idler (Fig. 3–10).
Fig. 3–9 Remove Clutch Plate and Lining
11. Remove inside clutch plate,

hardened race and thrust bearing
(Fig. 3–11).
PI–01130 PI–01131
Fig. 3–10 Remove Secondary Idler Sprocket Fig. 3–11 Remove Inside Clutch Plate
600, 600D, 610, 611 Loader

55 of 214
12. Remove seal and engine cover
(Fig. 3–12).
13. Remove four hydraulic lines to

clutch shafts (Fig. 3–13).
14. Remove clutch shaft holding nut

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

lead seal (Fig. 3–14).
16. Remove clutch actuator linkage

(Fig. 3–15).

17. Remove center spring (Fig. 3–15).
C–01784
Fig. 3–12 Remove Seat and Engine Cover
PI–01132 C–01803
Fig. 3–13 Remove Hydraulic Lines Fig. 3–14 Remove Clutch Shaft Holding Nut
B–01830
Fig. 3–15 Remove Actuator Linkage and Spring
600, 600D, 610, 611 Loader

56 of 214 80
18. Remove clutch shaft and actuator
bar (Fig. 3–16).
Assembly
1. Install clutch actuator nuts to

actuator linkage.
PI–01133
a. Hold actuator linkage in same Fig. 3–16 Remove Clutch Shaft and Actuator Bar
position as when it is installed
in loader (Fig. 3–17).
b. Put the right hand thread

actuator nut into the right yoke
and the left hand thread
actuator nut into the left yoke
(Fig. 3–17).
c. Install spring washers behind

eye of yokes and install on
actuator bar. Washer must fit
over shoulder of screw (Fig.
3–18).
B–02594
d. Turn clutch shafts into Fig. 3–17 Install Actuator Nuts

actuator nuts.
2. Install assembly into loader.
a. Hold right clutch shaft in right

hand and left clutch shaft in
left hand (Fig. 3–19).
b. Place the system in clutch

shaft holes (Fig. 3–19). B–01828
Fig. 3–18 Install Spring Washers
PI–01133
Fig. 3–19 Install Clutch Shaft and Actuator Bar
600, 600D, 610, 611 Loader

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

onto clutch shaft.
e. Tighten clutch shaft nuts so

shaft will not turn by hand
pressure (Fig. 3–20). C–01803
Fig. 3–20 Tighten Holding Nuts
f. Connect actuator linkage to

lever linkage (Fig. 3–21).
3. Make adjustment of clutch shaft

for positive clutch engagement.
a. Put direction control lever 3–4

inches forward of neutral B–01830
positron (Fig. 3–22).
Fig. 3–21 Connect Actuator Linkage to Lever Linkage
b. Turn rear clutch shaft for full

thread contact between WITH THE CONTROL LEVER HAND
activating threads (Fig. 3–22). 4’’ GRIP 4’’ FORWARD OF NEUTRAL,
THE REAR ACTUATING NUT AND
THREAD SHOULD HAVE ‘‘FULL
c. To turn clutch shaft, install THREAD CONTACT’’ AS SHOWN.
castle nuts onto clutch shaft
with castle toward the loader.
Put cotter pins through castle
nut and shaft. Use wrench on
nut to turn shaft.
FULL THREAD CONTACT
d. When rear clutch shaft has
correct adjustment, tighten
the clutch shaft holding nut to
225 foot–pounds (305 Nm).
Use a wrench on castle nut to
prevent clutch shaft from
turning. Install inside clutch
plate over rear shaft.
PI–01134
FULL THREAD CONTACT
WRONG RIGHT WRONG
PI–01135
Fig. 3–22 Adjusting Clutch Shaft
600, 600D, 610, 611 Loader

58 of 214 80
e. Put grease on thrust bearing
to hold it in hub.
f. Install inside clutch plate (Fig.

3–23).
g. Put front clutch plate in

alignment with rear clutch Thrust Thrust
plate with control levers in Bearing Washer
neutral position. to check use
a straight edge across face of
clutch plate (Fig. 3–24). Turn
PI–01131
front clutch shaft for
alignment. When alignment is Fig. 3–23 Install Inside Clutch Plate
correct hold clutch shaft and
tighten holding nut to 225
foot–pounds (305 Nm).
4. Install secondary idler sprocket

(Fig. 3–25).

5. Install secondary chain over idler PI–01136
sprocket under sprocket on front Fig. 3–24 Alignment Of Clutch Plates
clutch and over sprocket on rear
clutch (Fig. 3–26).
6. Connect chain with press fit

connectors (Fig. 3–27).
7. Tighten chain for 1/4 inch play with

hand pressure.
PI–01130 PI–01190
Fig. 3–25 Install Secondary Idler Fig. 3–26 Install Secondary Chain
8. Install clutch linings to inside
clutch plates. Lining should fit
loosely over shoulder of inside
clutch (Fig. 3–28).
Lining
Shoulder
PI–01191 B–01946
Fig. 3–27 Install Chain Connector Fig. 3–28 Install Clutch Lining
600, 600D, 610, 611 Loader

9. Install outside clutch plates (Fig.
3–29).
10. Install thrust bearings and thrust

races on outside clutch plates
(Fig. 3–30).
11. When installing new thrust PI–01129 PI–01128

bearings, also install new thrust
races for bearings. Check Parts Fig. 3–29 Install Outside Clutch Plate Fig. 3–30 Install Thrust Bearing & Race
Manual to get correct races used
with heavy bearings.
12. Check alignment nut so it moves

free by finger pressure. When not
free, put in vise to press loose (Fig.
3–31).

13. Install alignment nut (Fig. 3–30).
PI–01137 B–02414
Fig. 3–31 Check Alignment Nuts Fig. 3–32 Install Castle Nuts & Roll Pins
14. Install castle nut (Fig. 3–32).
15. Use straight–edge to check

alignment of clutch sprockets with
primary drive sprocket (Fig. 3–33).
16. Install primary drive chain with

1/4’’ (6.4 millimeter) play at 10
pounds (4.5 kilogram) of pressure PI–01138 PI–01140
(Fig. 3–34). Fig. 3–33 Check Clutch Sprocket Alignment Fig. 3–34 Check Primary Drive Chain
17. Install side panel (Fig. 3–35).
18. Check control lever movement

(Fig. 3–36). Adjust clutches see
Page 3–2.
B–02023 PI–01026
Fig. 3–35 Install Side Panel Fig. 3–36 Check Control Lever Movement
600, 600D, 610, 611 Loader

60 of 214 80
19. Install clutch caps.
20. Install hydraulic lines to clutch

shafts (Fig.. 3–37).
21. Install seat and engine cover.
3–3 INSTALLING CLUTCH NEEDLE

BEARINGS.
1. Remove clutches. (See Page PI–01132
3–32). Fig. 3–37 Install Hydraulic Lines
2. Remove old bearings (Fig. 3–38).
3. Press a new bearing in from each

side of clutch plate with numbered
end of bearings to outside on each
end of hub.
4. Bearing ends should be even with

edge of hub (Fig. 3–39).
3–4 DRIVE BELT INSTALLATION

(Split Shaft) PI–01279
Fig. 3–38 Remove Old Bearings Fig. 3–39 Bearing Installed
(On loaders equipped with canopy
(ROPS) see 1 and 2, ‘‘Removal of
Driven Sheave’’, page 3–11).
1. Put belt in low speed position (Fig.

3–40).
2. Remove outside half of variable

speed drive sheave and hydraulic
assembly (Fig. 3–41).
3. Clean cylinder and hose.

B–01959 PI–01142
4. Disconnect hose fittings and seal Fig. 3–40 Drive Belt In Low Speed Position Fig. 3–41 Variable Speed Drive Sheave
off cylinder inlet and hose to keep
out dirt.
5. Inspect spacer between variable Spacer

speed cylinder and holding
bracket and frame bracket. When
installing, install spacers in same
position as when removed (Fig.
3–42).
6. Loaders with swivel coupler,

remove swivel then remove
holding nut to split sheave (Fig.
3–43).
D–01053 C–01242
Fig. 3–42 Variable Speed Spacers Fig. 3–43 Variable Speed Swivel Coupler
600, 600D, 610, 611 Loader

7. Remove spilt jackshaft connector
block (Fig. 3–44). Install in same
position as removed. Check
punch marks and put toward
sheave.
8. Remove old belt between split in

shaft (Fig. 3–45).
9. Install new belt between split in PI–01143 B–01966

shaft. Fig. 3–44 Remove Connector Block Fig. 3–45 Removing Drive Belt
10. Install split jackshaft connector

block. Use new lock nuts. Tighten
bolts evenly to 18–20 foot–pounds
(27 Nm).
11. Use a round rod to pull belt onto

drive sheave (Fig. 3–46).

12. Make adjustment of spring tension
on driven sheave. PI–01144 B–01965
Fig. 3–46 Install Belt On Drive Sheave Fig. 3–47 Alignment Of Sheaves Halves
13. Install outside half of drive sheave.

Replace the holding nut and
tighten to 130 (176 Nm) WITH BELT AT HALF VARIABLE
foot–pounds torque (Fig. 3–41). LAY A STRAIGHTEDGE ALONG
THE DRIVEN SHEAVE AS SHOWN
14. Inspect alignment of balance

marks on sheaves (Fig. 3–47).
15. Connect hydraulic hose.
16. Check alignment of sheaves (Fig.

3–48).
PI–01027
Fig. 3–48 Check Alignment Of Sheave
600, 600D, 610, 611 Loader

3–5 REMOVAL OF DRIVEN SHEAVE
1. Raise lift arms and install cylinder

support bracket. Remove drive
belt (Page 3–9).
2. Remove rear bolts from canopy

and tilt canopy forward onto a
support (Fig. 3–49).
3. Remove clutch caps from left side B–01537

of loader (Fig. 3–2).
Fig. 3–49 Tilting The Canopy
4. Remove left side panel (Fig. 3–5).
5. Loosen the primary idler and remove chain (Fig. 3–6).
6. Use puller to remove drive sprocket of primary drive (Fig. 3–50).
7. Remove hydraulic line to left rear clutch shaft.

8. Remove the battery.
PI–01145
9. Remove hydraulic tubeline(s) from variable speed valve. Fig. 3–50 Removing Sprocket
10. Loosen set screw in bearing

locking collar (Fig. 3–51).
11. Remove bearing locking collar

from jackshaft by rotating 3/4 turn
(Fig. 3–52).
12. Remove jackshaft connector

block. (Check position of block
when making installation (Fig.
3–44).
PI–01146 PI–01147
Fig. 3–51 Loosening Set Screw Fig. 3–52 Remove Locking Collar
13. Drive jackshaft half toward center
of loader with soft hammer (Fig.
3–53).
14. Remove jackshaft with sheave

through top of machine (Fig.
3–54).
PI–01151 PI–01152
Fig. 3–53 Removing Jackshaft Fig. 3–54 Jackshaft And Sheave Removal
600, 600D, 610, 611 Loader

3–6 INSTALLING OF DRIVEN SHEAVE
1. Put sheave and jackshaft half into loader (Fig. 3–54).
2. Install a variable speed belt over the jackshaft (Fig. 3–45).
3. Install connector block punch marked ends together (Fig. 3–44).
4. Use new lock nut and tighten evenly to 18–20 foot–pounds (27 Nm).
C–01782
Fig. 3–55 Install Drive Sprocket
5. Install outside drive sheave half.
6. Inspect alignment of balance marks and connect hydraulic hose (Fig. 3–47).
7. Install sprocket on end of jackshaft (Fig. 3–55).
8. Check alignment of sprocket with outside clutch sprocket (Fig. 3–56).

9. Install primary drive chain (Fig. 3–27).
10. Primary chains should be tightened to 1/8’’ (3,0 mm) play with light hand PI–01149
pressure (Fig. 3–34).
Fig. 3–56 Check Alignment Of Sprockets
11. Install side panels (Fig. 3–35).
13. Check alignment of drive and

driven sheaves (Fig. 3–48)
a. When not in alignment put
variable speed belt to half
speed position.
b. Stop engine.
c. Loosen set screws on hub of
stationary half of sheave.
Move sheave for alignment
(Fig. 3–57).
B–02682
Fig. 3–57 Adjustment Of Driven Sheave
600, 600D, 610, 611 Loader

3–7 DRIVEN SHEAVE DISASSEMBLY
Remove sheave and shaft from loader Plate
(tapered jackshaft) (see page 33)
1. Remove lubricant fitting (Fig.
3–58).
2. Remove three spring retainer nuts

and plate (Fig. 3–58).
Retainer Nut
3. Remove spring (Fig. 3–58). Set Screw
Roll Pin
4. Remove moveable half of sheave C–01015
from shaft (Fig. 3–58). Fig. 3–58 Driven Sheave Breakdown
5. Remove sheave retaining nut

(Fig. 3–58).
6. Remove stationary sheave half by

holding shaft and hitting end on a
block of wood (Fig. 3–59).
3–8 ASSEMBLY OF DRIVEN SHEAVE
(TAPERED JACKSHAFT)
1. Drive the shaft into tapered hole

on stationary half of sheave (Fig.
3–60).
2. Check to see that key is in place.

PI–01154 PI–01155
3. Install retainer nut. Tighten to 130 Fig. 3–59 Remove Sheave Half Fig. 3–60 Install Shaft
foot–pounds (176 Nm).
4. Install moveable half of a sheave

on shaft. Inspect seals and
bushings (Fig. 3–61).
5. Install spring and retainer plate

(Fig. 3–61).
6. Loosen nut on one guide bolt to

start spring retainer nut over plate.
(Use new lock nuts, (Fig. 3–62).
7. Tighten nut to its original position.
8. Install other spring retainer nuts C–01851 PI–01156

then tighten nuts until they are Fig. 3–61 Spring And Retainer Plate Fig. 3–62 Install Spring Retainer Plate
even with ends of bolts (Fig.
3–63). (Use new lock nuts.)
9. Install lubricant fitting and turn

spring to position as shown in
Figure 3–64.
C–01798 PI–01157
Fig. 3–63 Tighten Nuts Fig. 3–64 Install Spring And Fitting
600, 600D, 610, 611 Loader

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

3–58).
3. Remove spring.
4. Separate sheave.
3–10 ASSEMBLY OF DRIVEN
SHEAVE (STRAIGHT JACKSHAFT)
1. Inspect seals and bushing on
sheave. B–01958
Fig. 3–65 Movable Half of Sheave
2. Install movable half of sheave
(Fig. 3–65).
3. Install spring (Fig. 3–61).
4. Loose nut on one guide bolt to start spring retainer nut (use new lock nuts)

(Fig. 3–62).
5. Tighten nut to its original position.
6. Install other spring retainer nuts then tighten until all are even with end of
bolts (Fig. 3–63). (Use new lock nuts.)
7. Install lubrication fitting (Fig. 3–64).
3–11 DRIVEN SHEAVE ALIGNMENT

Instructions for tapered jackshaft.
1. Remove clutch caps.
B–01960
2. Remove left side panel.
Fig. 3–66 Remove Connector Block
3. Remove primary chain.
4. Remove sprocket retainer bolt

and use puller to remove sprocket WITH BELT AT HALF VARIABLE
from end of jackshaft. LAY A STRAIGHTEDGE ALONG
THE DRIVEN SHEAVE AS SHOWN
5. Loosen set screws in locking
collar.
6. Remove bearing collar by turning

it in opposite direction of shaft
rotation.
7. Remove nuts from connector

block (Fig. 3–66).
8. Move jackshaft for alignment (Fig.

3–67).
9. Use new lock nuts on connector

block and tighten to 18–20 PI–01027
foot–pounds (27 Nm) (Fig. 3–66).
Fig. 3–67 Sheave Alignment
600, 600D, 610, 611 Loader

10. Check alignment again.
11. Install bearing locking collar.
12. Tighten set screws in collar.
13. Install jackshaft sprocket.
14. Use washers for alignment of drive sprocket with outside clutch sprocket.
(Fig. 3–56).
15. Install retainer washer and bolt.
16. Install primary chain.
B–02571
17. Tighten chain to 1/4 inch (6.4 mm) free play.
Fig. 3–68 Remove Bearing Housing Nuts
18. Install side cover.
3–12 JACKSHAFT BEARING INSTALLATION

2. Remove side panels.
3. Remove primary chain.

4. Remove sprocket retainer bolt.
5. Use pullers to remove drive sprocket from end of jackshaft.
B–02579
6. Loosen set screws from locking collar. Fig. 3–69 Remove Bearing Housing
7. Remove bearing locking collar by turning opposite of shaft rotation

8. Remove four nuts holding bearing housing (Fig. 3–68).
9. Remove bearing and housing from shaft (Fig. 3–69).
10. Remove bearing from housing (Fig. 3–70).
11. Install new bearing vertically into housing. Check to see that bearing moves
free in housing (Fig. 3–71).
12. When bearing will not move free make replacement of housing.
13. Check rotation of bearing in housing (Fig. 3–70).
14. Inspect to see that offset hub of bearing is toward outside of loader (Fig. PI–01150
3–72).
Fig. 3–70 Remove Bearing From Housing
15. Install housing to inner side of
chain housing. Use new sealing
washers (Fig. 3–69).
16. Install bearing locking collar and
turn with shaft rotation to tighten.
17. Tighten set screws in collar.
18. Install sprocket on jackshaft.
19. Install sprocket retain or bolt.
21. Install side panel.
A–01104 PI–01150
Fig. 3–71 Install Bearing Vertically Fig. 3–72 Check Offset Hub Position
600, 600D, 610, 611 Loader

3–13 REMOVAL OF VARIABLE
DRIVE SHEAVE WITH ROTO SWIVEL
INSIDE (600, 610 Gasoline and
Diesel, Serial Number 72319 and Up)
1. While engine is running move
1
variable speed control lever
forward, then stop engine.
2. After engine has stopped, hold

lever to rear and pulling up on drive
belt to open drive sheave.
3. Remove round side cover by 2

variable speed sheave.
4. Press in on the end cap (Fig. 3–73,

Item 1) and remove snap ring
(Item 2).
B–01831
5. Slide the moving half sheave off Fig. 3–73 Remove Outer Half Sheave Snap Ring
the stationary half sheave.
6. Remove the large snap ring and

pull the piston with swivel out of
the stationary half sheave (Fig.
3–74).

7. Remove bolt and holding washer
from end of variable speed (Fig.
3–75).
8. Remove washer from bolt.
9. Install bolt in crankshaft and turn

until it hits the bottom.
10. Install 1/4 inch (6.4 mm) bolts into

holes in fixed sheave hub.
11. Install puller on half sheave behind

bolts and remove (Fig. 3–76).
B–01829
12. Remove stationary half sheave Fig. 3–74 Remove Piston With Swivel
from engine crankshaft.
PI–01158 PI–01160
Fig. 3–75 Remove Bolt and Washer Fig. 3–76 Remove Stationary Half Sheave
600, 600D, 610, 611 Loader

3–14 ROTO–SWIVEL DISASSEMBLY
1. Remove snap ring that holds
roto–swivel into the piston (Fig.
3–77, Item 1)
2. Remove roto–swivel (Fig. 3–77, 5

2 1
Item 2). 3 4
3. Remove snap ring on end of
roto–swivel (Fig. 3–77, Item 3).
4. Inspect two ball bearings.
5. Inspect end of roto–swivel.

3–15 ROTO–SWIVEL ASSEMBLY
1. Install roto–swivel seals (Fig.
3–77, Item 4) B–01114
Fig. 3–77 Roto–Swivel Parts
2. Install two ball bearings (Fig.
3–77, Item 5).
3. Install snap ring on end of

roto–swivel (Fig. 3–77, Item 3).

4. Install roto–swivel into piston.
6 5 2 4
5. Install snap ring that holds
roto–swivel into piston (Fig. 3–77, 1
Item 1).
3–16 ASSEMBLY PROCEDURES
FOR 610 VARIABLE SPEED WITH
ROTO–SWIVEL INSIDE
3
1. Install piston to stationary half
sheave (Fig. 3–78, Item 1).
2. Install internal snap ring (Fig.

3–78, Item 2)
C–01342
3. Install stationary half sheave on
engine shaft. Fig. 3–78 Variable Speed W/Inside Swivel
4. Remove 1/4 inch (6.4 mm) bolts in holes on stationary half sheave.
5. Remove bolt in crankshaft.
6. Put machined washer on bolt. (Inspect and make sure to use correct
machined washer.)
7. Install bolt and washer (Fig. 3–78, Item 3).
8. Install moving half sheave (Fig. 3–78, Item 4).
9. Install end cap (Fig. 3–78, Item 5).
10. Push moving half sheave in and install snap ring (Fig. 3–78, Item 6).
11. Install hose to control valve and roto–swivel.
600, 600D, 610, 611 Loader

3–17 REMOVAL OF VARIABLE
SHEAVE WITH ROTO–SWIVEL
OUTSIDE (600 Gasoline, LP and
Diesel; Serial Number 67253–72318)
2
1. While engine is running move
variable speed control lever 1
forward, then stop engine.
2. After engine has stopped, hold

lever to rear and pull up on drive
belt to open drive sheave.
3. Remove round side cover by C–01242

variable speed sheave. Remove
hydraulic hose from Roto Swivel. Fig. 3–79 Variable Speed W/Outside Swivel
4. Push in on movable half sheave so that snap ring can be removed (Fig. 3–79,
Item 1).
5. After snap ring has been removed pull movable half sheave, with piston
assembly, out of loader.
6. Remove holding bolt and washer from end of crankshaft (Fig. 3–79, Item 2).
Use puller to remove stationary half sheave.
To install variable sheave reverse the above procedure. Always use new O–ring

seals, lubricated with oil, when assembling variable speed parts.
3–18 REMOVAL OF FRAME SUPPORT VARIABLE SHEAVE (600 Gasoline
and LP; serial Number 62796–67252)
1. With engine running move variable speed control lever forward then stop Fig. 3–80 Variable Speed (600 Gas & LP)
engine. After engine has stopped move lever back to release hydraulic
pressure.
2. Remove the hydraulic hose from 2
variable speed assembly. 1
3. Remove the support bracket for

variable speed and pull complete
assembly with movable half 3
sheave out of loader (Fig. 3–80).
4. Remove holding bolt and washers

from end of crankshaft (Fig. 3–81,
Item 1).
5. Use puller tool to remove C–01016

stationary half sheave.
Fig. 3–81 Variable Speed Frame Support
6. To disassemble piston assembly, use a driver to force cylinder shaft out of

bearing cap (Fig. 3–81, Item 2).
7. Loosen clamp and remove rubber cover and plate.
8. Unscrew gland (Fig. 3–81, Item 3) and remove piston assembly.
To install variable sheave reverse the above procedure. Always use new O–ring
seals, lubricated with oil, when assembling variable speed parts.
600, 600D, 610, 611 Loader

3–19 AXLE REMOVAL (FRONT
AXLE)
1. Lift side of loader from which axle

is to be removed (Fig. 3–82).
2. Empty oil from side tank reservoir

(Fig. 3–83).
3. Disconnect linkage from control

pedals (Fig. 3–84).
4. Remove floor panels and pedal B–02573 B–01507

guard (Fig. 3–85). Fig. 3–82 Raising Loader Fig. 3–83 Reservoir Oil Drain Plug
5. Remove wheel from axle.
7. Remove side panel.
8. Loosen secondary drive chain

(Fig. 3–86).
9. Loosen final drive chains (Fig.

3–87).

10. Remove dust cap at end of axle
(Fig. 3–88).
C–01781 C–01780
11. Remove cotter pin from castle nut
and remove castle nut bushing Fig. 3–84 Remove Pedal Linkage Fig. 3–85 Remove Floor Panels
and washer (Fig. 3–89).
PI–01162 PI–01163
Fig. 3–86 Secondary Drive chain Fig. 3–87 Final Drive Chain
PI–01165 PI–01166
Fig. 3–88 Remove Hub Cap Fig. 3–89 Remove Nut, Bushing & Washer
600, 600D, 610, 611 Loader

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

axle housing (Fig. 3–91).
14. Pull axle from loader using puller

(Fig. 3–92).
PI–01171
15. Remove sprocket nut and lock
washer from loader (Fig. 3–93). Fig. 3–90 Remove Sprocket Holding Nut
16. Remove final drive sprocket from

loader.
3–20 AXLE BEARING AND SEAL

INSTALLATION
1. Remove housing from axle by

hitting end of axle against a wood
block (Fig. 3–94).
2. Remove axle bearing from shaft PI–01169 B–01623

use puller (Fig. 3–95).
Fig. 3–91 Remove Hub Nuts Fig. 3–92 Remove Axle
3. Install new bearing and seal in
housing (Fig 3–96).
PI–01173 PI–01169
Fig. 3–93 Sprocket Nut & Locking Washer Fig. 3–94 Remove Axle Housing
PI–01174 PI–01170
Fig. 3–95 Remove Axle Housing Fig. 3–96 Install New Bearing & Seal
600, 600D, 610, 611 Loader

4. Check that seal lips are forwards
inside, seal should be even with Gasket Sprocket
outer edge of hub (Fig. 3–99). Nut
Seals
Locking
5. Use a pipe larger than axle shaft to Washer
drive housing and bearing on shaft
(Fig. 3–100).
6. Install bushing on axle (Fig. 3–97

or Fig. 3–98)
C–01007
3–21 INSTALLATION OF AXLE
Fig. 3–97 Rear Axle Breakdown
1. Install final drive sprocket in drive
housing (Fig. 3–101).
2. Install axle into loader (Fig. 3–102)
3. Install locking washer and holding

nut on the axle.
Brake Hub

C–01607
Fig. 3–98 Front Axle Breakdown (Loaders with Brakes)
PI–01175
Fig. 3–99 Check Position of Seal Fig. 3–100 Install Hub and Bearing
C–01805 C–01804
Fig. 3–101 Install Final Drive Sprocket Fig. 3–102 Install Axle
600, 600D, 610, 611 Loader

4. Check that holding nut threaded
part is away from sprocket (Fig.
3–103).
1.46” 1.37”
5. Inspect locking washer for
diameter as front and rear are
different (Fig. 3–104). No Thread
Area
6. Install outside housing to loader
frame (Fig. 3–105).
7. Begin installation of sprocket Rear Axle Front Axle

holding nut tighten by hand.
A–02438 A–02437
8. Install inside bearing, bushing and Fig. 3–103 Position Of Sprocket Nut Fig. 3–104 Locking Washer Diameter
washer (Fig. 3–106).
9. Install castle nut onto end of axle

and tighten until bearing has some
preload. (Turn axle to feel
pre–load). (Fig. 3–107).
10. Install cotter pin and dust cap on

inside end of axle. Inspect O–ring
in cap and make replacement if
damaged (Fig. 3–108).

11. Use axle wrench to hold nut and
turn axle to tighten against
sprocket inside gear housing (Fig.
3–109).
PI–01167 PI–01176
12. Lock locking nut with lock washer Fig. 3–105 Install Housing Frame Fig. 3–106 Installing Inner Bearing
(Fig. 3–110).
13. Tighten all chains (refer to drive

chain adjustment).
16. Install floor panels (Fig. 3–85).
17. Connect control pedal linkages

(Fig. 3–84).
3–22 AXLE SPROCKET REMOVAL & B–02412 PI–01165

INSTALLATION Fig. 3–107 Check Bearing Pre–Load Fig. 3–108 Install Dust Cap
Follow steps in axle removal and axle

installation. Check new sprocket for
number of teeth and length of spline
against old sprocket to be sure of
correct replacement.
B–02418 PI–01278
Fig. 3–109 Tightening Sprocket Nut Fig. 3–110 Bending Locking Washer
600, 600D, 610, 611 Loader

3–23 LOWER JACKSHAFT
REMOVAL
1. Lift side of loader being worked on

and remove wheels.
2. Remove clutch caps (Fig. 3–111).
3. Remove side panel (Fig. 3–112).
PI–01026 B–02023
4. Empty the oil from side tank Fig. 3–111 Remove Clutch Cap Fig. 3–112 Remove Side Panel
reservoir (Fig. 3–113).
5. Remove linkage from control

6. Remove floor panels (Fig. 3–115).
7. Loosen and remove all the drive

chains use chain breaker tool (Fig.

3–116).
8. Remove front clutch assembly Drain Plug

(Fig. 3–117). B–01507 C–01781
Fig. 3–113 Empty Oil From Tank Fig. 3–114 Remove Pedal Linkage
9. Remove jackshaft holding bolts

(Fig. 3–118).
C–01780 PI–01181
Fig. 3–115 Remove Floor Panels Fig. 3–116 Using Chain Breaker Tool
PI–01131 PI–01180
Fig. 3–117 Remove Clutch Assembly Fig. 3–118 Remove Holding Bolts
600, 600D, 610, 611 Loader

10. Use tank spreader to spread gear
11. Remove lower jackshaft sprocket

from loader by lifting forward and
up (Fig. 3–119).
3–24 LOWER JACKSHAFT THE IMPRINTED

SPROCKET REPAIR NUMBERS ON THE
BEARINGS MUST BE
1. To install bearings in double TOWARD THE OUT–
sprocket: SIDE OF THE SPROCKET
a. Remove old bearings. PI–01177 PI–01182

b. Install new bearings with Fig. 3–119 Remove Sprocket Fig. 3–120 Install Bearing Hubs
numbers to outside of
sprocket. Bearing should be
seated 1/16’’ (1.9 mm) in from
end of hub. Install a bearing
from each end of hub (Fig.
3–120).
c. Install large sprocket to
multiple sprocket. Use a liquid
sealant on threads of bolts
(Fig. 3–121).

d. Tighten bolts to 55 ft–lbs. (75
Nm) (Fig. 3–123).
e. Install safety wire (Fig.
3–123). PI–01178 PI–01183
Fig. 3–121 Liquid Sealant On Bolts Fig. 3–122 Tightening Sprocket Bolts
f. Inspect shaft for wear and
make replacement when
necessary (Fig. 3–124).
g. Install inside thrust washer
(Fig. 3–125).
h. Install sprocket assembly
onto shaft with large sprocket
toward plate (Fig. 3–126).
i. Install outside thrust washers
(Fig. 3–126).
j. Install outside holding plate
(Fig. 3–127).
PI–01179 PI–01185
3–25 LOWER JACKSHAFT Fig. 3–123 Install Safety Wire Fig. 3–124 Install New Shaft
INSTALLATION
1. Install jackshaft assembly into
gear tank (Fig. 3–119). Use a tank
spreader to open tank wider for
easier installation.
2. Move sprocket so hole in plate are

in line with holes in inner side wall
(Fig. 3–119).
3. Install holding bolts through holes

in inner side wall.
4. Install final drive chains (Fig.

3–128).
PI–01186 PI–01187
Fig. 3–125 Install Thrust Washer (Inside) Fig. 3–126 Install Thrust Washer (Outside)
600, 600D, 610, 611 Loader

5. Connect chain with press fit
connector (Fig. 3–128).
6. Install outside holding bolts

(Fig. 3–129). Use heat treated
fine thread bolts, with lock nuts.
7. Install front clutch assembly

(Fig. 3–130).
PI–01188 PI–01189
Fig. 3–127 Install Outside Holding Plate Fig. 3–128 Install Drive Chain
8. Install secondary drive chain by
using wire (Fig. 3–131).
9. Connect secondary chain with

press fit connector (Fig. 132).

11. Connect primary chain with
press fit connector. PI–01180 PI–01131
Fig. 3–129 Install Holding Bolts Fig. 3–130 Install Front Clutch
12. Tighten all chains (See Drive

Chain Adjustment page 3–26).
15. Install floor panels (Fig. 3–133). PI–01190 PI–01191

Fig. 3–131 Install Secondary Chain Fig. 3–132 Install Chain Connector
16. Connect control pedal linkage

(Fig. 3–134).
C–01780 C–01781
Fig. 3–133 Install Floor Panels Fig. 3–134 Connecting Control Pedal Linkage
600, 600D, 610, 611 Loader
3–26 DRIVE CHAIN ADJUSTMENT
a
2. Remove side panels.
3. To make adjustment of final

drive chains:
a. Loosen outside holding

bolts for lower jackshaft PI–01163 C–01781
(Fig. 3–135).
Fig. 3–135 Loosening Outside Holding Bolts Fig. 3–136 RemoveControl Pedal Linkage
b. Remove linkage to control

c. Remove floor panels (Fig.

3–137).
d. Loosen inside holding bolts

for lower jackshaft (Fig.
3–138).

e. Use a pry bar in hole of
large sprocket to tighten
chain (Fig. 3–139). C–01780 PI–01164
Fig. 3–137 Remove Floor Pedals Fig. 3–138 Loosen Inside Holding Bolts
f. Tighten chain to 1/4’’ (6.4
mm) play with 40 pounds
(18.1 Kg) of pull (Fig.
3–140).
g. Tighten two outside and

two inside holding nuts to 40 LBS.
110 ft.–lbs. (149 Nm) (Fig.
3–141).
1/4’’
h. Put control levers in
neutral. Turn wheels to
check play (Fig. 3–142).
PI–01192 PI–01194
Fig. 3–139 Tightening Chain Fig. 3–140 Drive Chain Adjustment
PI–01193 B–02592
Fig. 3–141 Tightening Holding Nut Fig. 3–142 Check For Freeplay
600, 600D, 610, 611 Loader

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

PI–01162
e. Put control levers in neutral and turn wheel to check play. Fig. 3–143 Loosening Secondary Idler
5. Adjustment of primary chain.
a. Loosen two nuts holding

primary idler (Fig. 3–146).
b. Pull idler sprocket forward

to tighten chain.

c. Tighten to 1/8’’ (3.2 mm) play
with light hand pressure (Fig.
3–147).
PI–01141 PI–01195
d. Tighten two idler holding nuts Fig. 3–144 Secondary Idler Adjustment Fig. 3–145 Secondary Chain Adjustment
to 30 ft.–lbs. (41 Nm) (Fig.
3–146).
e. Inspect idler sprocket for clearance.
f. Turn wheels on loader and check play. Inspect for chain clearance of
other parts in system.
6. Install side panels.
PI–01139
8. Install floor panels. Fig. 3–146 Loosening Primary Idler
9. Connect control pedal linkage.
10. Start loader, engage control lever and check operation.
11. Inspect for oil leaks.
12. Shut off loader and remove blocks.
PI–01140
Fig. 3–147 Primary Chain Adjustment
600, 600D, 610, 611 Loader
3–27 BRAKE ASSEMBLY
1. Remove safety step.
2. Disconnect control pedal linkage.
3. Remove floor panels.
4. Remove four brake drum bolts

(Fig. 3–148). B–01950
Fig. 3–148 Remove Drum Bolts Fig. 3–149 Remove Cotter Pin, nut & Washers
5. Remove cotter pin, axle nut and washer (Fig. 3–149).
6. Remove brake shoe holding plate (Fig. 3–150).
7. Remove brake drum holding hub (Fig. 3–151).
3–28 ASSEMBLY OF BRAKE

1. Install axle seal and O–ring (Fig. 3–152).
B–01947
2. Install brake drum holding hub (Fig. 3–151). Fig. 3–150 Remove Shoe Holding Plate
3. Install brake shoe holding plate

(Fig. 3–148).
4. Install washer and axle nut (Fig.

3–149).
5. Tighten castle nut to preload

bearing to 65 ft.–lbs. (88 Nm).
6. Install cotter pin.
7. Install brake drum (Fig. 3–153). C–01808

Fig. 3–151 Remove Drum Holding Hub Fig. 3–152 Install Seal and O–ring
B–01949
Fig. 3–153 Install Brake Drum
600, 600D, 610, 611 Loader

3–29 BRAKE ADJUSTMENT
Adjust
1. To make adjustment, turn To
control levers clockwise (Fig. Tighten
3–154). Brake
2. When all adjustment is taken

up:
a. Disconnect hydraulic
control pedal linkage.
b. Remove floor panels.
c. Loose n locking nut on

control linkage.
d. Remove lower pin

adjustment clevis (Fig.
3–154).
Lower

e. Turn control lever counter Clevis
clockwise until threads are
at beginning of adjustment
(Fig. 3–154).
C–01844
f. Shorten clevis. Fig. 3–154 Brake Lever and Pedal Linkage
g. Linkage rod adjustment is

correct when control
handle is tight when
engage.
600, 600D, 610, 611 Loader

610,611ServiceManual#6556276–DriveSystemSectionPages3–29
600, 600D, 610, 611 Loader

HYDRAULIC SYSTEM
Paragraph Page
Number Number
ASSEMBLY OF HYDRAULIC PUMP
(WEBSTER PUMPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–21 4–11
ASSEMBLY OF VARIABLE SPEED CONTROL
VALVE SEAL REPLACEMENT WITH CONTROL VALVE . . 4–16 4–7
CARTRIDGE RELEASE ADJUSTMENT . . . . . . . . . . . . . . . . . . 4–9 4–4
CHECKING CONDITION OF HYDRAULIC PUMP . . . . . . . . . 4–6 4–3
CHECKING PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . 4–12 4–6
CHECKING THE CONDITION OF HYDRAULIC SYSTEM . . 4–5 4–2
CHECKING THE PRESSURE SETTING OF
THE CARTRIDGE RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7 4–4
CHECKING VARIABLE SPEED VALVE
HYDRAULIC
PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10 4–5 SYSTEM
CONTROL VALVE SEAL INSTALLATION . . . . . . . . . . . . . . . . 4–17 4–8
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–20 4–10
DISASSEMBLY OF VARIABLE SPEED CONTROL VALVE . 4–15 4–7
HYDRAULIC CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . 4–1 4–1
HYDRAULIC CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . 4–26 4–13

HYDRAULIC LIFT OR TILT CYLINDER DISASSEMBLY . . . . 4–24 4–13
HYDRAULIC PUMP ALIGNMENT
(500 ELECTRIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–27 4–14
HYDRAULIC PUMP ALIGNMENT
(600 WISCONSIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–28 4–15
HYDRAULIC PUMP ASSEMBLY (CESSNA PUMP) . . . . . . . . 4–23 4–12
HYDRAULIC PUMP DISASSEMBLY
(CESSNA PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–22 4–12
HYDRAULIC PUMP SERVICE
(WEBSTER PUMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–19 4–10
HYDRAULIC SYSTEM (600 ELECTRIC &
600 DIESEL W/PETTER ENGINE) . . . . . . . . . . . . . . . . . . . . . 4–4 4–2
HYDRAULIC SYSTEM (600 & 610 DIESEL
W/DEUTZ ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3 4–1
HYDRAULIC SYSTEM (600, 610 GASOLINE & LP GAS) . . . 4–2 4–1
INSTALLATION OF CYLINDER SEALS . . . . . . . . . . . . . . . . . . 4–25 4–13
INSTALLING VALVE SPOOL SEALS IN THE
VARIABLE SPEED CONTROL VALVE . . . . . . . . . . . . . . . . . . 4–18 4–9
600, 600D, 610, 611 Loader

600, 600D, 610, 611 Loader

HYDRAULIC SYSTEM
4–1 Hydraulic Circuit Operation
The loader is equipped with full–flow
positive–pressure lubrication to
clutches and drive system. Oil is
pulled from reservoir through a filter
into the pump. The pump forces it
through the control valves and
clutches, back to reservoir. This is
with hydraulic controls in neutral (Fig.
4–1 & 4–2).
When a control is activated, oil is sent
into one end of selected cylinders. Oil
flows from other end of cylinders
back to valve group through the
clutches and into reservoir. When the
valve is put in neutral, oil is stopped
in cylinder, holding the load in place
and the oil again moves from pump
through valves and clutches and into
reservoir. A release valve in the
system prevents an overload in the
circuit.
4–2 Hydraulic System (600, 610
Gasoline and LP Gas) Fig. 4–7
Hydraulic Fluid Flow)

Oil is pulled from reservoir through
the hydraulic oil filter (Item 1) by
hydraulic pump (Item 2), pump
moves fluid to control valves (Item 3,
4 & 5). The main release valve (Item
6) is a valve set to open when a B–01156
control valve is activated and the Fig. 4–1 Hydraulic System (600, 610 Loaders)
cylinders hit the end of their stroke, or
when lifting a load larger than the
loader’s capacity. When moving
variable speed control lever forward,
oil is moved by variable speed control
valve (Item 5) to variable speed
cylinder (Item 7). This moves the
drive sheaves together, giving faster
ground speed. Pulling lever back will
slow ground speed. A check valve in
the clutch lubrication manifold (Item
8) holds a pressure of 20 PSI (138
kPa) to the drive clutches.
4–3 HYDRAULIC SYSTEM (600
and 610 Diesel W/Deutz Engine)
(Fig. 4–2 Hydraulic Flow)
Oil flows from the reservoir through
the hydraulic oil filter (Item 1) by
hydraulic pump (Item 2).
Pump moves fluid to control valve
(Item 3, 4 & 5). The main release
valve (Item 6) is a valve set to open
when a control valve is activated and
the cylinders hit the end of their
stroke, or when lifting a load larger
than the loader’s capacity. When
moving variable speed control lever
forward, oil is moved by variable
speed control valve (Item 5) to
variable speed cylinder (Item 7). This
moves the drive sheaves together,
giving faster ground speed. Pulling
lever back will slow ground speed. A
check valve in the clutch lubrication
manifold (Item 8) holds the pressure
of 20 PSI (138 kPa) to the drive
clutches. B–01157
Fig. 4–2 Hydraulic System (600, 610 Deutz)
600, 600D, 610, 611 Loader

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

under the flame to support it
before starting check.
W–2316–0498
4–4a RESTRICTOR FOR TILT B–01158

HYDRAULIC CIRCUIT (Grapple
Operation Only) Fig. 4–3 Hydraulic System (600 Peter)
This restrictor is installed to slow the

flow of hydraulic oil through the tilt
cylinders when tilting the Bob–Tach
forward. Install as shown in (Fig.
4–4a).
4–5 CHECKING THE CONDITION
OF HYDRAULIC SYSTEM
The hydraulic tester must be used to
check pump output, release setting,
cylinder seals and control valve
condition.
1. Connect tester to the auxiliary
hydraulic tubelines at rear of
loader (Fig. 4–4).
a. Connect a hose from rear
auxiliary tubelines to outlet
opening of tester (Item 1).
b. Connect a hose from front
tubeline to inlet opening of
tester (Item 2).
2. Start the engine.
3. Operate at full throttle.
4. Hold down front of auxiliary
control pedal (Item 3).
5. Turn pressure control valve on
tester at a slow rate.
6. Check flow reading on tester.
7. Flow reading must be even until
master relief valve opens.
When valve opens, flow rate will
A–01107
drop suddenly.
Fig. 4–4 Testing Hydraulic System
600, 600D, 610, 611 Loader

86 of
Revised Feb. 80214 –4–2– Service Manual
8. See chart below for volume of oil
a new pump will move until master
relief valve opens.
RECOMMENDED HYDRAULIC OIL
FLOW RATE
600 (Gasoline or
LP Gas) . . . . . . . . 10 gal/min (38L)
610 . . . . . . . . . . . . . 11 gal/min (42L)
600 (Diesel)
Deutz . . . . . 10 to 11 gal/min (42L)
Petter 10 ga/min (38L) at 300 RPM
600 (Electric) . . . 8 gal/min (30L) at
1750 RPM
9. An old pump will show a lower
reading.
10. Close pressure control valve.

Pressure should be between B–1661R
1700–1750 PSI (11720–12066 Fig. 4–4a Restrictor
kPa).
4–6 CHECKING CONDITION OF HYDRAULIC PUMP (Fig. 4–5)
1. Remove the hoses from the auxiliary tubeline.
2. Connect hoses to tilt cylinder tubelines at the rear of loader.

a. Connect hoses from inlet opening of tester to rear tilt tubeline (Item 1).
b. Connect hose from outlet opening of tester to front tilt tubeline (Item 2).
3. Place a stop (5/16 by 1’’ [7,9 mm

by 25,4 mm] long carriage bolt)
between clutch lubrication
manifold tee and master release
valve tubeline fitting (Item 3).
4. Open pressure control.
1
5. Start the engine and run at low
idle.
6. Hold back of tilt control pedal
down (Item 4).
2
7. Slowly turn the pressure control
on tester clockwise to increase
the system pressure.
IMPORTANT Tilt
3
Lines
When this method is used
there is no relief valve in the
system. Closing the pressure
control rapidly will cause
over maximum pump
pressure and can damage the 4
pump or tester. Do not
increase the pressure over
2000 PSI (13790 kPa).
I–2175–0598
8. When reading of pump pressure

is above 1850 PSI (17755 kPa) Tilt
pump is good. Refer to flow chart Pedal A–01108
above. Fig. 4–5 Testing Hydraulic System
600, 600D, 610, 611 Loader

87 of 214
Revised Feb. 80 –4–3– Service Manual
4–7 CHECKING THE PRESSURE
SETTING OF THE CARTRIDGE
RELEASE (In Lift and Auxiliary
Control Valve)
1
1. Connect tester to auxiliary
tubelines at rear of loader (Fig.
4–6).
2
a. Connect a hose from the rear
auxiliary line to outlet opening
of tester (Item 1).
b. Connect a hose from front
auxiliary line to inlet opening 3
of tester (Item 2).
Aux.
2. Leave the stop (5/16 x 1’’ [7,9 mm Lines
x 25,4 mm] long carriage bolt)
between the clutch lubrication
manifold tee and master release
valve tubeline (Item 3). 4
3. Open pressure control on tester.
4. Start the engine and run at 1/4

throttle.

5. Hold front of auxiliary control
pedal down (Item 4).
Auxiliary
6. Turn the pressure control on the Pedal
tester until cartridge release valve Fig. 4–6 Checking Lift and Auxiliary Release Pressure
opens. the pressure setting of this
cartridge release should be 1800+100 or –100 PSI (12411±690 kPa).
Do not forget to remove the stop

(carriage bolt) from between the
WARNING clutch lubrication manifold tee and
the master release valve tubeline.
4–8 MASTER RELEASE VALVE ADJUSTMENT

1. Remove hex cap from valve body (Fig. 4–7).
2. Remove spring and shim from behind it (Fig. 4–7).
3. Adding a shim will increase system pressure and installing a thin shim for Fig. 4–7 Release Valve Adjustment
thick shim will decrease pressure. Adding a .010 (2,5 mm) inch thick shim
will increase pressure approximately 100 PSI (690 kPa).
4. Install cap and check pressure. Make further adjustments when needed.
4–9 CARTRIDGE RELEASE ADJUSTMENT
1. Remove hex cap from front of valve (Fig. 4–8).
2. Remove shim from behind it. Shim

3. Adding a shim will increase pressure. Installing a thin shim for a thick shim
will decrease pressure.
4. Install cap and check pressure. Make further adjustments when needed. Cap
C–01051
Fig. 4–8 Remove Hex Cap
600, 600D, 610, 611 Loader

WARNING
Variable speed closing
pressure must not be over
maximum on variable speed
internal roto–swivel (See
below). It must never be above
the pressure necessary to
shift from full low speed to full
high speed position in four
seconds at full engine RPM.
W–2318–0598
4–10 CHECKING VARIABLE SPEED

VALVE PRESSURE ADJUSTMENT
(Variable Speed Swivel Couplings)
When making adjustment and checking
variable speed closing and holding
pressure, it is important first to note
which type of swivel coupling is used.
The internal roto–swivel type needs a
higher closing and holding pressure to

operate properly. (See warning note
above.)
4–11 Variable Speed Control Valve
With Holding Pressure Release C–01765 C–01760
Valve Fig. 4–9 Adjust Variable Speed Valve
The variable speed sheave must close in the drive sheave in four seconds at full
engine RPM. When belt comes up faster than four seconds, decrease closing
pressure. When belt comes up slower than four seconds, increase the closing
pressure. This adjustment is made by turning pressure release valve adjustment
in or out (Fig. 4–12). When making this adjustment, do not go over 550 PSI (3792
kPa) pressure. Inspect tension on holding release spring. Plunger must not move
in valve body when belt is in high variable speed position with full engine RPM (Fig.
4–10).
1. Install a 1000 PSI (7000 kPa) pressure gauge into the rear opening of
variable speed control valve (Fig. 4–9).
2. Start the engine and run at full throttle.
3. Move the variable speed control lever forward to high speed position (Fig. C–01760
4–9). Hold it there.
Fig. 4–10 Variable Speed Valve Spring
4. The indicator on the gauge should show closing pressure of 350–550 PSI
(2400–3800 kPa)
5. Return the lever to neutral.
6. Check holding release valve pressure.
7. Twist the hose to increase pressure to holding release valve. Check

pressure increase for maximum reading.
8. The reading should be 750–775 PSI (5170–5340 kPa).
600, 600D, 610, 611 Loader

4–12 CHECKING PRESSURE ADJUSTMENT (Variable Speed Control Valve
with no Holding Pressure Valve ) (Fig. 4–11)
Using this type valve, oil is moved into variable speed cylinder at a variable speed
closing pressure of 375–400 PSI (2585–2758 kPa) or 475–500 PSI (3275–3447
kPa) on variable speed with rotor–swivel inside. Check the variable speed closing
pressure using same method as when checking the variable speed valve with
holding pressure release (Steps 1 through 5).
4–13 VARIABLE SPEED CLOSING PRESSURE ADJUSTMENT (Variable

Speed Control Valve with or with no Holding Release Valve) (Fig. 4–12)
1. To increase the closing pressure, turn the set screw plug into the valve a little
at a time (Item 1).
2. Turn the plug into maximum

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

3. If plug becomes overtight while
increasing the pressure, a shim
can be added between the set
screw plug and spring (Fig. 4–13).
C–01053 B–02413
4. To lower the closing pressure,
loosen the set screw plug until the Fig. 4–11 Variable Speed Valve Fig. 4–12 Adjust Closing Pressure
pressure is 400 PSI (2758 kPa) or
475–500 PSI (3275–3447 kPa)
on variable sheave with
roto–swivel inside.
5. If the plug becomes loose,

causing an oil leak, shorten the
spring by grinding off the end of it.
Do not overheat the spring when
grinding.
4–14 VARIABLE SPEED HOLDING

RELEASE PRESSURE SETTING
(Fig. 4–12) (600 PSI [4137 kPa] C–01053
Minimum) Fig. 4–13 Add Shims To Jet Screw Plug
1. To increase pressure setting, turn hexagon nut in spring holding bracket so

it moves toward spring. Turn nut 1/4 rotation then check pressure setting.
2. If nut runs out of threads, put a washer between nut and spring.
3. To decrease pressure setting, turn hexagon nut so that it moves away from
spring.
NOTE: A loader used under heavy loads, may require more than 600 PSI
(4137 kPa) holding pressure to prevent variable speed leak down
and O–ring damage in holding pressure nut. On loaders equipped
with variable speed, having roto–swivel inside, holding pressure
should be 700 PSI (4826 kPa).
600, 600D, 610, 611 Loader

4–15 DISASSEMBLY OF VARIABLE SPEED CONTROL VALVE (Seal
Replacement with Control Valve in the Bobcat)
1. Remove seat and seat plate (Fig. 4–14).
2. Remove variable speed control lever linkage rod.
3. Remove temperature release valve bracket (Fig. 4–15, Item 1).
4. Remove push rod guide and push rod (Fig. 4–15, Item 2).
C–01784
Fig. 4–16 Remove Seat and Plate
5. Use magnet to remove ball and spring (Fig. 4–15, Item 3).
6. Remove end cap and spring (Fig.

4–15, Item 4). 5
1
7. Install seal on dust cap end of
spool (Fig. 4–15, Item 5).
4
8. Move spool back to install new

back seal (Fig. 4–18).
Ball & Spring Guide

9. Move spool forward to install new 3 2
seal on clevis end of spool (Fig. Push Rod C–01053
4–17). Fig. 4–15 Variable Speed Valve Parts
NOTE: Do not push spool beyond its limits as this can cause seal to go into
groove of valve and result in damage to seal.
10. Move spool back into normal position.
4–16 ASSEMBLY OF VARIABLE SPEED CONTROL VALVE, SEAL

REPLACEMENT WITH CONTROL VALVE IN THE BOBCAT (With Holding
Release Valve) (Fig. 4–15)
1. Install spring assembly and end cap (Item 4)

PI–01199
2. Install new seals on push rod and push rod guide (Item 2) Fig. 4–16 Install Back Seal
3. Place ball on small round end of spring (Item 3). (Use grease to hold spring
and ball to end of rod guide.)
4. Install push rod and rod guide (Item 2).
5. Install push rod bracket (Item 1).
6. Connect variable speed control linkage.
7. Make pressure adjustments. (See Paragraph 4–13 and 4–14). PI–01201

Fig. 4–17 Install Front Seal
600, 600D, 610, 611 Loader
4–17 CONTROL VALVE SEAL
INSTALLATION (Fig. 4–18, 4–19) (For 1 3
Tilt, Lift Valve and Auxiliary Cylinder 2
Control Valve) 4
1. Remove rubber cap from back of
valve (Item 1).
2. Remove large snap ring and stop

disc (Item 2 & 3).
3. Remove spring assembly bolt.

Centering spring lock washer,
stop collar, spring and stop C–01240
washer (Item 4)
Fig. 4–18 Lift and Auxiliary Valve Parts
4. Push spool into housing from front
of valve until front seal is out, then
remove front seal (Fig. 4–20).
1 3
5. Pull spool out of housing from front 2
of valve and remove back seal 4
(Fig. 4–21).
6. Clean both seal grooves. 5

7. Install spool, through front of

housing with spring fastening end
of spool first (Fig. 4–19, Item 5).
8. Push spool into valve until end of

spool is at back seal groove. C–01049
Fig. 4–19 Tilt Valve Parts
9. Install a new seal in back groove. Place U cup of seal toward valve body (Fig.
4–22).
10. Inspect seal for smooth fit.
11. Push spool into housing from front until front groove can be seen.
NOTE: Do not push spool back more than necessary or back seal will be
damaged.
12. Install a new front seal, keep the U cup side of the seal toward valve body
(Fig. 4–23).
13. Inspect seal for smooth fit. PI–01197

Fig. 4–20 Removing Front Seal
14. Push spool through the housing until 1/4 inch of spool surface is shown at
front of valve.
15. Install spring assembly bolt,
spring, lock washer, stop collar,
spring and lock washer (Fig. 4–18,
4–19).
16. Tighten assembly bolt.
17. Install stop disc and snap ring (Fig.

4–18, 4–19, Item 2 & 3).
18. Install rubber cap (Fig. 4–18,

4–19, Item 1).
PI–01198 PI–01199
Fig. 4–21 Removing Spool Fig. 4–17 Install Back Seal
600, 600D, 610, 611 Loader

4–18 INSTALLING VALVE SPOOL
SEALS IN THE VARIABLE SPEED 2 4
CONTROL VALVE 6
1. Remove four bolts from valve

spring cap (Fig. 4–23, Item 1).
2. Remove screw, lock washer, flat

1 3
washer, spring and stop collar 5
from end of spool (Fig. 4–23,
Items 2, 3, 4, 5 & 6).
C–01053
Fig. 4–23 Variable Speed Valve Parts
3. Pull valve spool out of housing (Fig. 4–24).
4. Check position of U cup of seals for correct installation of new seals.
5. Remove worn seal (Fig. 4–24).
6. Install spool in housing with no seals. Push spool into housing until seal
groove can be seen at cap end of valve.

7. Install a new seal into back groove (Fig. 4–25).
PI–01204
8. Push seal into housing and pull spool into valve housing (Fig. 4–25). Fig. 4–24 Remove Valve Spool
9. Pull valve spool toward control end of valve until front seal groove is visual.
10. Install a new front seal (Fig. 4–26).
11. Push seal into housing and spool into place (Fig 4–26).
12. Install collar, spring, washers and screw. Tighten screw (Fig. 4–23, Items 2,
3, 4, 5 & 6).
13. Check that washer moves free on spool. PI–01205

Fig. 4–25 Install Seal On Valve Spool
14. Install cap and four bolts (Fig. 4–23, Item 1).
15. Check cap for proper alignment. It must be correctly centered over end of
spool.
PI–01206
Fig. 4–26 Install Front Seal
600, 600D, 610, 611 Loader
a–19 HYDRAULIC PUMP SERVICE
4
(Webster Pump) 1
3
For seal replacement in hydraulic
pump, follow the below procedure 2 5
(Fig. 4–27).
6 8
7 9
4–20 DISASSEMBLY 11
1. Clean outside of pump. 12
2. Make mark on edges of cover 4

so it can be installed again in
same position.
10
3. Remove the pilot plate and seal
(Fig. 4–28). C–01042
Fig. 4–27 Hydraulic Pump Breakdown (Webster)
4. Pull the pump drive shaft out of

pump (Fig. 4–29). The ball
bearing will come with it.

5. Remove all bolts from pump
body (Fig. 4–30).
6. Install two bolts into shaft side

and turn them in several turns
by hand. Hit sharply on heads of
two screws, first one, then the
other, then first one again (Fig.
4–31). When the dowels are
loose, remove the screws and
separate the plates.
7. Inspect the gears, shafts and

bearings.
PI–01207 PI–01210
Fig. 4–28 Remove Pilot Plate and Seal Fig. 4–29 Remove Drive Shaft
8. When needle bearings are bad
remove and install new needle
bearings (Fig. 4–32).
9. When cover and body plates

are worn, grind them smooth.
10. Install new gears after grinding

cover and body.
PI–01211 PI–01212
Fig. 4–30 Remove Body Bolts Fig. 4–31 Separating Pump Plates
600, 600D, 610, 611 Loader

4–21 ASSEMBLY OF HYDRAULIC
PUMP (Webster Pump) LETTERED
SIDE UP 1/16’’
1. Wash off pump parts and dry
with air.
2. Install ball bearings to pump

drive shaft.
3. Install drive shaft into the body

(Fig. 4–29).
PI–01214
Fig. 4–32 Install New Bearings Fig. 4–33 Replace Seal In Pilot Plate
4. Make seal replacement in pilot
plate (Fig. 4–33).
5. Set pump body with machined

face up (Fig. 4–34).
6. Install key in drive shaft and

lower drive gear over it (Fig.
4–34).

7. Install idler gear and shaft
PI–01215 PI–01216
8. Install gear plate over gears Fig. 4–34 Machined Faced Of Pump Fig. 4–35 Install Idler Gears
and put scratch marks in a line.
9. Install dowel pins through large

holes in gear plate (Fig. 4–36).
10. Install cover plate over shaft.

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

machine screws. PI–01217 A–01076
Fig. 4–36 Install Dowel Pins Fig. 4–37 Install Body Bolts
600, 600D, 610, 611 Loader

4–22 HYDRAULIC PUMP
DISASSEMBLY (Cessna Pump) 10
1 4 5
1. Remove key from pump drive
2. Clean outside of pump. Put marks

in a line across edges of cover,
gear plate and body (Fig. 4–39).
10
3. Hold pump in a vise shaft down. 9 6
Remove bolt which holds the 3 9
pump plates together (Fig. 4–41).
2
C–01090
4. Remove pump from vise. Fig. 4–38 Hydraulic Pump Breakdown (Cessna)
Separate pump plates by hitting
shaft onto a wooden block (Fig.
4–40).
5. Remove these items (Fig. 4–38) from front plate of pump.
a. Diaphragm (Item 1)
b. Springs (2)* Steel Balls (2) (Item 2 & 3)
c. Gaskets (2) (Item 4)
d. Molded V Seal (Item 5)
e. Shaft Seal (Item 6)
6. Clean and dry all pump parts.

7. Inspect pump drive shaft for a broken key way. Inspect pump drive shaft and
idler gear shaft at bearing points and seal areas. When shaft diameter
measures less than .6850 inch (17,5 mm) is in the bearing area, make
replacement.
A–01008
8. Inspect the gear faces for wear. Check with following chart: If gear width is
below these figures, replace the gears. Fig. 4–39 Marking Pump Sections
a. Pump Model B24387–OBAA .636 inch (16,3 mm)
b. Pump Model 15509–OEBA .636 inch (16,3 mm)
c. Pump Model 15510–OEBA .767 inch (19,6 mm)
9. Inspect the back plate for wear. When worn more than .0015 inch (,038 mm)
install new plate.
10. Check inside diameter of bearings in place. When inside diameter is worn
more than .691 inch (17,5 mm) install new plates.
11. Inspect chambers in gear plates for wear. When chamber is worn, more than
1.719 inches (43,6 mm) install new gear plate.
4–23 HYDRAULIC PUMP ASSEMBLY (Cessna Pump)
1. When assembling install new parts as follows: (Fig. 3–28).
a. Diaphragm (Item 1) PI–01218
b. Gaskets (2) (Item 4)
c. V Seat (Item 5) Fig. 4–40 Holding Pump In Vise
d. Shaft Seal (Item 6)
2. Install V seal into groove in front plate. Install seal with open part of V toward
plate (Item 5).
3. Put gasket into V seal (Item 4).
4. Drop steel balls into seat and place springs over balls (Item 2 & 3).
5. Place diaphragm over gasket, bronze face up (Item 1).
6. Make sure diaphragm fits inside raised edge of V seal.
7. Put oil on gears and slide them into front plate bearings.
8. Put grease on both faces of gear plates and install plates over gears (Item PI–01219
9 & 10).
Fig. 4–41 Separating Pump Parts
600, 600D, 610, 611 Loader

9. Check marks on side of plates
when installing, to be sure they
are in alignment (Fig. 4–39).
10. Slide backplate over gear shaft
until dowel pins are engaged.
11. Install bolts and tighten them
evenly to 25 ft.–lbs. (34 Nm)
(Fig. 4–40).
12. Install pump drive shaft seal
over shaft being careful not to
cut rubber sealing edge.
13. Seat seal with a plastic
hammer. B–02587
Fig. 4–42 Remove Lift Cylinder
4–24 HYDRAULIC LIFT OR TILT
CYLINDER DISASSEMBLY
1. Remove hydraulic cylinder from

loader (Fig. 4–42).
2. With spanner wrench, remove
head from cylinder (Fig. 4–43).
3. Pull shaft and piston assembly
from cylinder housing (Fig.
4–44).

4–25 INSTALLATION OF
CYLINDER SEALS
1. File and grind a bevel on A–01896 B–02583

shoulder at piston end of Fig. 4–43 Remove Cylinder Head Fig. 4–44 Remove Cylinder Shaft W/Piston
cylinder shaft (Fig. 4–45).
2. Remove all rough areas off
3. Put teflon piston seals in warm
oil or water for several minutes
before installing.
4–26 HYDRAULIC CYLINDER

ASSEMBLY (Fig. 4–47)
1. Install cylinder head seals and

place cylinder head carefully
onto cylinder shaft (Item 1 thru
6). PI–01221a PI–01221b
2. Install bushing onto shaft (lift Fig. 4–45 Filing Bevel On Shaft Fig. 4–46 Remove Marks on Shaft
cylinder only) (Item 7).
3. Install piston seals and place
piston onto end of cylinder shaft
(Items 8, 9 & 10). 1
3 2
4. Install piston locking nut and 9 7
tighten it (Item 11). 8
10
5. Install piston and shaft into 11
cylinder.
6. Install cylinder head into
cylinder case. Be careful not to
damage seals.
7. Tighten cylinder head with
spanner wrench (Fig. 4–43).
4 5 6 C–01052
Fig. 4–47 Hydraulic Cylinder Assembly
600, 600D, 610, 611 Loader
4–27 HYDRAULIC PUMP ALIGNMENT (500 ELECTRIC)
1. Remove hydraulic pump and pump holding plate from motor housing (Fig.
4–48).
2. Remove two pump holding bolts.
3. Install bolt with lock washers and put nuts on pump side. Tighten nuts and
spot weld them to plate (Fig. 4–49).
4. Remove pump from holding plate.
5. With center punch mark 8 drill holes. They should be positioned 2 per every
90° around the bell housing so set screws will seat against four machined PI–01229
bosses on motor housing (Fig. 4–50).
Fig. 4–48 Removing Pump and Plate
6. Remove bell housing from motor (Fig. 4–50).
7. Drill 8 holes and turn a 1/4 inch

(6,4 mm) by 20 tap through them
(Fig. 4–50).
8. Start 1/4 inch (6,4 mm) set screws

in holes.
9. Remove worn pump drive adapter

from motor shaft (Fig. 4–51).

10. Attach bell housing to motor and
tighten holding bolts evenly (Fig.
4–52).
PI–01231 PI–01230
11. Install pump holding plate to Fig. 4–49 Spot Weld Nuts Fig. 4–50 Drilling & Tapping Housing
12. Install a new pump drive adapter

into end of motor shaft. Hit bolt
lightly with hammer and tighten.
13. Fasten a dial indicator to shaft so

that indicator arm slides on inner
circumference of holding plate for
pump (Fig. 4–54).
14. Using a long bar, force variable

speed drive belt into driven
sheave. This will loosen belt in
drive sheave so motor shaft may
be turned by hand. PI–01232 PI–01233
Fig. 4–51 Remove Old Adaptor Fig. 4–52 Install Bell Housing
15. Turn motor shaft by hand noting
dial indicator reading. Make
adjustment of 8 set screws to
move bell housing until a
maximum total indicator reading
of .004 inch (,102 mm) is made.
16. Tighten housing holding bolts (Fig.

4–53).
17. Remove dial indicator.
18. Install hydraulic pump on holding

plate (Fig. 4–48).
PI–01234 PI–01235
Fig. 4–53 Install Holding Plate Fig. 4–54 Using Dial Indicator
600, 600D, 610, 611 Loader

4–28 HYDRAULIC PUMP Alignment Tool
ALIGNMENT (600 Wisconsin)
NOTE: Use pump alignment tool.
(See parts book for correct
tool).
1. Remove pump and drive coupling

from engine (Fig. 4–60).
2. Slip tool over pump shaft to bottom

C–01809 B–02564
3. Place pump into holding bracket
and hold it in position (Fig. 4–56). Fig. 4–55 Install Alignment Tool Fig. 4–56 Install Pump and Tool
4. Slide tool over accessory drive

5. To make correct alignment do the

following:
a. Loosen holding bolts for pump
bracket and move bracket up
or down or rotate on
accessories shaft.

b. With bracket installed loosely
shim between bracket and
engine block, or grind off block
to make alignment. Tighten B–02567 C–01809
bolts (Fig. 4–57).
Fig. 4–57 Shimming Holding Bracket Fig. 4–58 Check Shaft Alignment
6. With brackets fastened and pump fastened in place, check alignment
between pump and drive shaft from distributor (Fig. 4–58). Add or remove
shims or grind away block on engine with alignment is correct.
7. Remove pump tool and install drive coupling half loosely to accessory drive
shaft.
8. Install other half coupling loose on pump (do not install rubber), and push
pump into bracket. Install and tighten pump fastening bolts.
9. Pull each coupling half together on drive and pump shaft. Check for .025 inch B–02421
(,63 mm) clearance between each half of coupling. use feelers gauge and Fig. 4–59 Using Feeler Gauge
check all the way around coupling while not turning shaft (Fig. 4–59).
10. When alignment is correct,

remove pump and tighten set
screws in drive hub evenly to 9
ft.–lbs. (14 Nm) (Fig. 4–60).
11. Install pump into bracket and hold

with fasteners and bolts (Fig.
4–60).
12. Check again for .025 inch (,63

mm) clearance between each
coupling half (Fig. 4–59).
E–01089
B–01230
Fig. 4–60 Pump Installation
600, 600D, 610, 611 Loader

4–29 37° Flare Connections
610,611ServiceManual#6556276–HydraulicSystemSection
Use the following procedure to tighten flare fittings:

(1) Tighten the nut until it makes contact with the seat. Mark a Line on Nut
Flats of Both Nuts
(2) Make a line across the flats of both the male and female parts of the
connection (Fig. 4–61).
(3) Use chart below to find correct tightness needed.
Tighten to Correct
Amount from Chart
Fitting Thread Size Rotate No. Of Hex Flats
9/16–18 2
3/4–16 2
7/8–14 1–1/2–2
A–01897
1–1/16–12 1 Fig. 4–61 Tightening Flared Fittings
1–5/16–12 3/4–1
4–30 Tubelines and Hoses

Make replacement of tubelines that have damage. A bent tubeline will cause oil O–ring
to flow at a slow rate and will cause an increase in heat and a decrease in hydraulic
action. Make replacement of hoses when wear or damage is present. Use correct
clamps to hold tubelines and hoses in position.
4–31 Installing O–Rings

When installing this fitting, lubricate the O–ring with oil. Loosen the jam nut, screw
the fitting into place and connect the tubeline first, before tightening the jam nut.
Tighten the jam nut until it and the washer are tight against the face of the opening O–ring
(Fig. 4–62). The O–ring must be pushed into the space shown.
A–01852
Fig. 4–62 Straight Thread Seal
600, 600D, 610, 611 Loader

WISCONSIN ENGINE SERVICE
Paragraph Page
Number Number
ASSEMBLY OF VAPORIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–21 5–9
ASSEMBLY FUEL BOWL AND INTAKE ASSEMBLY . . . . . . . 5–9 5–3
ASSEMBLY THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . 5–10 5–4
ASSEMBLE VAPORIZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20 5–8
ASSEMBLY OF ENGINE AFTER RECONDITIONING
INSTALLATION OF VALVE TAPPETS . . . . . . . . . . . . . . . . . . 5–42 5–14
ASSEMBLY OF FUEL BOWL AND THROTTLE BODY . . . . . 5–11 5–4
CARBURETOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 5–5 5–2
CARBURETOR RECONDITIONING . . . . . . . . . . . . . . . . . . . . . 5–6 5–2
DISASSEMBLE THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . 5–7 5–2
DISASSEMBLING VAPORIZER . . . . . . . . . . . . . . . . . . . . . . . . . 5–19 5–8
DISASSEMBLY OF THE FUEL BOWL . . . . . . . . . . . . . . . . . . . 5–8 5–3
ENGINE RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–24 5–11
FUEL FILTER LOCK–OFF DISASSEMBLY . . . . . . . . . . . . . . . 5–23 5–10
GOVERNOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 5–1
INSTALLATION OF ACCESSORIES . . . . . . . . . . . . . . . . . . . . . 5–58 5–18 WISCONSIN
INSTALLATION OF AIR HOUSING . . . . . . . . . . . . . . . . . . . . . . 5–56 5–18 ENGINE SERVICE

INSTALLATION OF CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 5–43 5–14
INSTALLATION OF CAMSHAFT GEAR . . . . . . . . . . . . . . . . . . 5–52 5–17
INSTALLATION OF CARBURETOR &
MANIFOLD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–55 5–18
INSTALLATION OF CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . 5–44 5–15
INSTALLATION OF CYLINDER BLOCKS . . . . . . . . . . . . . . . . 5–46 5–15
INSTALLATION OF CYLINDER HEAD . . . . . . . . . . . . . . . . . . . 5–54 5–17
INSTALLATION OF FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . 5–57 5–18
INSTALLATION OF GEAR COVER . . . . . . . . . . . . . . . . . . . . . . 5–53 5–17
INSTALLATION OF IDLER GEAR & SHAFT . . . . . . . . . . . . . . 5–51 5–17
INSTALLATION OF OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 5–49 5–16
INSTALLATION OF PISTON RINGS . . . . . . . . . . . . . . . . . . . . . 5–47 5–15
INSTALLATION OF PISTONS & CONNECTING RODS . . . . 5–48 5–16
INSTALLATION OF VALVES & SEAT INSERTS . . . . . . . . . . . 5–45 5–15
LP CARBURETOR ASSEMBLING . . . . . . . . . . . . . . . . . . . . . . . 5–17 5–6
LP CARBURETOR CLEANING AND INSPECTION . . . . . . . . 5–16 5–6
LP CARBURETOR DISASSEMBLY PROCEDURE . . . . . . . . 5–15 5–5
LP CARBURETOR RECONDITIONING . . . . . . . . . . . . . . . . . . 5–14 5–5
LP CARBURETOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13 5–5
LP CARBURETOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12 5–5
LP FUEL FILTER LOCK–OFF . . . . . . . . . . . . . . . . . . . . . . . . . . 5–22 5–10
OIL PAN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–50 5–16
REMOVAL OF ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . 5–26 5–11
REMOVAL OF AIR HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . 5–28 5–11
REMOVAL OF CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–32, 5–12
5–40 5–14
600, 600D, 610, 611 Loader

WISCONSIN ENGINE SERVICE (Cont’d)
Paragraph Page
Number Number
REMOVAL OF CARBURETOR & MANIFOLD . . . . . . . . . . . . . 5–29 5–12
REMOVAL OF CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 5–39 5–14
REMOVAL OF CYLINDER BLOCKS . . . . . . . . . . . . . . . . . . . . . 5–38 5–14
REMOVAL OF CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 5–30 5–12
REMOVAL OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–25 5–11
REMOVAL OF FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–27 5–11
REMOVAL OF GEAR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . 5–31 5–12
REMOVAL OF IDLER GEAR & SHAFT . . . . . . . . . . . . . . . . . . 5–33 5–12
REMOVAL OF OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–34 5–12
REMOVAL OF OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–35 5–12
REMOVAL OF PISTONS & CONNECTING RODS . . . . . . . . . 5–36 5–13
REMOVAL OF VALVE TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . 5–41 5–14
REMOVAL OF VALVES & SEAT INSERTS . . . . . . . . . . . . . . . 5–37 5–13
RETURN OF NORMAL COMPRESSION . . . . . . . . . . . . . . . . . 5–1 5–1
RETURN STORED ENGINE TO SERVICE . . . . . . . . . . . . . . . 5–4 5–2
STORAGE OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 5–2
VAPORIZER & PRIMARY REGULATOR SERVICE . . . . . . . . 5–18 5–8
600, 600D, 610, 611 Loader

5 WISCONSIN ENGINE SERVICE
5–1 RETURN OF NORMAL
COMPRESSION
On a new engine or on one which has
been out of operation for some time,
the oil may have run off cylinder walls
so that compression will be low. Loss
of compression will cause hard
starting. To correct, remove spark
plugs and add about a fluid ounce
(.03 kg) of engine oil through the
spark plug hole into each cylinder.
Turn the engine over several times by
hand for distribution of oil over the
cylinder walls. Then install spark
plugs and compression should be
correct.
B–02575
5–2 GOVERNOR ADJUSTMENT Fig. 5–1 Governor Adjustment
The control rod between the

governor and carburetor must have
proper adjustment length, or
governor will not operate correctly. Cotter Pin
With engine stopped, the governor

spring will hold the fly weight in, and
the control rod must be of such length
as to hold the carburetor throttle wide
open. The adjustments can be
checked by disconnecting the control
rod from the governor lever, and
pushing the rod toward the
carburetor as far as it will go. This will
open the throttle. The governor lever
must then be moved as far as
possible in the same direction. All of
this is done with the rod disconnected
from the lever while holding both
parts in above position (Fig. 5–1). the
rod must be turned into the swivel
block on the carburetor, until the bent
end of the rod is in line with the hole B–02601
in the lever. Then turn rod in two more
turns. Install rod into hole in governor Fig. 5–2 Governor Lever Installation
lever and install the cotter pin (Fig.
5–2). With the governor lever pushed
toward the carburetor as far as it will
go, there must be about 1/16 of an
inch (1,5 mm) clearance between the
throttle lever and the stop pin on the 12
carburetor (Fig. 5–3). The clearance
will cause the lever to bounce back 10
from stop pin, rather than stop
against pin, when a load is applied to 8
idling engine.
6
The governor lever has 12 holes (Fig. 1/16’’ Clearance
5–4) for fastening governor spring. 4
For correct operation, the spring Stop Pin
must be fastened to number 10 hole 2
in the arm. This would set engine
speed to 2400 RPM under load.
B–02605 A–01833
Fig. 5–3 Stop Pin Clearance Fig. 5–4 Governor Lever
600, 600D, 610, 611 Loader

5–3 STORAGE OF ENGINE
Oil Drain
Clean the outside of engine thoroughly. Plug
To protect the cylinders, pistons, rings

and valves from rust, a half and half
mixture of kerosene and engine oil
B–02599
should be put into pipe tap opening on
intake manifold (Fig. 5–5), while engine
is warm and running at low speed.
About 1/4 pint is (,4 ltr.) needed, or
enough to cause heavy blue smoke to
appear at the exhaust. Then shut off the
engine. This operation will cover the Fuel
above parts with a layer of oil to protect B–02597 Drain B–02608
them from corrosion. Fig. 5–5 Adding Oil Mixture Fig. 5–6 Draining System
Remove oil from oil pan and empty the fuel system (Fig. 5–6).
Idle Discharge Throttle Plate
5–4 RETURN STORED ENGINE TO SERVICE
Holes
Remove any sign of water from engine. Fill oil pan to full level with correct grade
of engine oil. Inspect spark plugs. Add fuel to tank and charge fuel system. Idle Air
5–5 CARBURETOR ADJUSTMENT

The main jet in carburetor is stationary and needs no adjustment. Adjustment of Idle Adjusting
the needle for idle jet should be made for best low speed operation while Idle Jet Needle

carburetor throttle is held closed by hand. Turning needle in nearer to its seat
results in a heavier concentration. Turning needle out away from its seat results
in a lighter concentration (Fig. 5–7).
5–6 CARBURETOR RECONDITIONING (Fig. 5–8) Idle Fuel (Pick–Up Passages) A–01810
Fig. 5–7 Carburetor Adjustment
1. Use a screwdriver to remove the
four bowl assembly screws (Item
1) and lock washers.
2. Raise throttle housing and

separate bowl to body gasket
(Item 2) from fuel bowl assembly, 10 9
then lift off throttle housing
carefully to prevent damage to 11 5
floats.
12
5–7 TO DISASSEMBLE THROTTLE
BODY 8
1. Push against end of float shaft 7
(Item 3) at side of hinge bracket to
force shaft through hinge bracket 4 3
(Fig. 4). Use a small screwdriver.
2. Remove float shaft from opposite 2 21

side. Remove float assembly
(Item 4) and fuel valve needle. 6
17 18
3. Remove bowl to housing gasket
(Item 2) from the machined 23
surface of throttle housing (Item 5) 22
then remove venturi (Item 6). 20
4. Remove fuel valve seat (Item 7) 16

with its fiber washer (Item 8). 15
14
5. Remove idle adjustment needle
(Item 9) and friction spring (Item 13
1
10) from side of throttle housing PI–01231
(Item 5).
Fig. 5–8 Carburetor Breakdown
600, 600D, 610, 611 Loader

6. Turn the throttle stop screw out (Item 11) until it is flush with end of lever (Item
12). Close throttle and mark levers and throttle body as a guide when
assembling parts.
NOTE: Do not remove throttle plate, throttle shaft and lever assembly, or
throttle packing holders from the throttle housing unless the shaft
is bent or other parts of assembly are damaged.
5–8 DISASSEMBLY OF THE FUEL BOWL
1. Remove the 1/2 inch (12,7 mm) plug (Item 13) from the bottom of the fuel
bowl. Remove the fiber washer (Item 14).
2. Remove main jet (Item 15) and fiber washer (Item 16) from the threaded
passage near the bottom of fuel bowl.
3. Remove main outlet jet (Item 17) with its fiber washer (Item 18) from center
of fuel bowl (11/32 inch (8,6 MM) wrench to remove).
4. Mark the choke bracket (Item 19), choke lever (Item 20) and air intake
housing as a guide to correct assembly.
5. Remove choke lever spring (Item 21). Close choke and remove choke plates
screw (Item 22), choke plate and shaft (Item 23). (Note the position of choke
plate stop in air intake).
6. Remove choke bracket screws and choke bracket.

Clean all metal parts, using a carburetor parts cleaner. Wash in solvent. Clean out
all passages and channels in carburetor with air. Reverse air flow through each
passage to remove all dirt.
NOTE: Never use a hard wire or drill to clean out jets. Inspect all parts and
install any damaged or worn parts. A repair kit should be used. For
correct repair kit, see Bobcat Parts Book.
5–9 TO ASSEMBLE FUEL BOWL AND INTAKE ASSEMBLY
1. Install choke shaft seal and holder using a bushing driver to drive holder into
housing until even with machined surface (Fig. 5–8). Follow same procedure
for other side.
2. Install choke shaft (Item 23) through seals and holders in position in air intake
body. Install choke plate (Item 22) in cut out of choke shaft. Check that choke
plate release valve is in same position as when it was disassembled. Install
choke plates screws using a small screwdriver.
3. Put choke shaft bracket (Item 19) over choke shaft and fasten bracket to air
intake in same position as when removed. Tighten screws.
4. Fasten choke lever spring (Item 21) to choke lever and choke bracket.
5. Put fiber washer (Item 18) over threads of main outlet jet (Item 17). Install
main outlet jet in bowl assembly and tighten.
6. Put fiber washer (Item 16) on main jet (Item 15) and install main jet in
threaded hole near bottom of bowl.
7. Install hex plug (Item 13) and gaskets (Item 14) and tighten.
600, 600D, 610, 611 Loader

5–10 TO ASSEMBLE THROTTLE BODY
1. Install throttle shaft seals and holding caps if these were removed during
disassembly. Using a bushing driver, lightly drive caps into housing until even
with machined surface (Fig. 5–9).
2. Install throttle shaft and lever assembly (Item 12) into throttle housing. Turn
shaft to fully open position.
3. Install throttle plate (Item 24) and turn to closed position. Hold plate with
fingers and start throttle plate screws (Item 11). Tighten them loosely with
a small screw driver. Center throttle plate in throttle bore and tighten screws.
Bushing
Driver B–02589
NOTE: Make sure bevel edges of throttle plate fit throttle bore when throttle
plate is closed. Fig. 5–9 Cap For Throttle Seal
4. Install idle adjustment needle (Item 9) and friction spring (Item 10) into the
threaded passage at side of throttle side of throttle housing. Turn needle in
slightly against its seat. Then, back needle out 1–1/4 turns as a temporary
adjustment.
1–5/32’’
5. Turn throttle housing and install fuel valve seat (Item 7) and fiber washer
(Item 8).
6. Put on a new throttle housing to fuel bowl gasket (Item 2) on machined

surface of bowl cover. Install fuel valve needle (Item 7) on its seat.
7. Install float assembly (Item 4) in position with float lever bushing in line with
holes in hinge bracket. Install float shaft (Item 3).
A–01800
8. For correct adjustment of fuel level in float chamber, check distance from the Fig. 5–10 Check Float Level
top of floats to machined surface of body (with not gasket) (Fig. 5–10). To
make adjustment use a needle nose pliers and bend lever on float body.
Idle Discharge Throttle Plate
Holes
NOTE: Do not bend or apply pressure to float bodies. When visually seen
from their free end, float bodies must be centered at right angles to
machined surface and must move free on float shaft. Idle Air
9. Install large opening end of venturi (Item 6) into throttle bore and position
venturi so the machined flat surface will be toward fuel bowl when bowl is Idle Adjusting
Idle Jet Needle
assembled.
5–11 ASSEMBLY OF FUEL BOWL AND THROTTLE BODY

Idle Fuel (Pick–Up Passages) A–01810
1. Place fuel bowl assembly on throttle housing assembly and put holes in
alignment in bowl flange with hole in gasket and cover. Fig. 5–11 Throttle Adjustment
2. Install four assembly screws and (Item 1) tighten them evenly.
3. Hold throttle lever in closed position and turn throttle stop screw (Fig. 5–11)
in until it contacts stop pin on throttle body. Turn screw in 1–1/2 more turns
as a preliminary adjustment. Install carburetor using three gaskets between
carburetor and intake manifold.
600, 600D, 610, 611 Loader

5–12 LP CARBURETOR SERVICE
The final regulator is built into the carburetor assembly. Fuel is measured to the
carburetor jets above pressure of atmosphere. The throttle shaft bearings are
provided with rubber seals.
5–13 CARBURETOR REMOVAL
1. Shut off fuel valve on fuel tank (Fig. 5–12).
2. Remove muffler from exhaust manifold.
3. Remove fuel line from carburetor and remove air cleaner hose.
B–02170
4. Remove choke and throttle linkage.
Fig. 5–12 LP Fuel Tank Shut–Off
5. Remove carburetor to manifold holding bolts and remove carburetor.
5–14 LP CARBURETOR
RECONDITIONING (Fig. 5–13)
The following tools are required for LP 9
carburetor repair:
1. C–166–52 alignment studs. 2
2. C–161–193 main jet wrench.

3. C–161–194 fuel valve lever 3
gauge.
11
6
(Get these tools from Zenith Carburetor
Dealers.)
4 4 10
5–15 DISASSEMBLY PROCEDURE 1
LP CARBURETOR
5 8
1. Turn throttle stop screw to left until
throttle plate is fully closed (Item
1).
2. Remove throttle plate screws 7
(Item 2) and throttle plate (Item 3). 13 15
3. Remove throttle shaft seal holders 14
and seals (Item 4). 12
4. Take out venturi holding screw
(Item 5) and remove venturi (Item
6).
5. Remove choke plate screw, choke B–01421
plate and choke shaft (Item 7). Fig. 5–13 LP Carburetor Parts
6. Remove idle adjustment needle and spring (Item 8).
7. Remove diaphragm cover assembly screws and complete diaphragm
assembly (Item 9).
8. Pull apart diaphragm assembly parts (Item 10).
9. Remove shaft holder, fuel valve shaft and fuel lever (Item 11).
10. Inlet orifice is held in position with a 8/32 allen screw. Loosen this screw
before removing inlet orifice (Item 12).
11. Remove inlet fuel valve stem and spring (Item 13).
12. Remove adjustment needle from main jet adjustment assembly (Item 14).
13. Use a 5/8 inch socket wrench to remove main jet adjustment housing (Item
15).
14. Use main jet wrench C–161–193 to remove main jet (Fig. 5–14).
600, 600D, 610, 611 Loader

5–16 CLEANING AND INSPECTION
Clean remaining parts in a parts cleaner
fluid and inspect for evidence of wear or Main Jet Tool
damage. Install all parts contained in (C–161–193)
repair kit and replace any damaged
parts. Repair kit #6519218 contains all
common items to be installed.
5–17 ASSEMBLE LP CARBURETOR
1. Install main jet with tool Adjustment O–ringFiber Washer

C–161–193 (Fig. 5–14). Needle
2. Place a new fiber washer on main

jet adjustment body. Install and
tighten with a 5/8 inch socket
wrench (Fig. 5–14). A–01813
Fig. 5–14 Install Main Jet
3. Put a new O–ring on main jet adjustment needle. Turn the adjustment needle
until it lightly contacts the seat, then back it out two to three turns (Fig. 5–14). Fuel Valve
Lever

4. Put a new rubber seal on fuel valve stem (Fig. 5–15).
Fuel
Valve
5. Install fuel valve spring on fuel valve and install valve, spring end first into
6. Place a new O–ring on inlet orifice and turn part way into housing (Fig. 5–18).
7. Install top of fuel valve lever into groove in valve stem. Install shaft and shaft Seal
holder (Fig. 5–15).
8. Put gauge C–161–194 on machined surface of housing. Make adjustment

of fuel valve lever to the .045–.055 inch (1,2–1,4 mm) position on gauge by A–01814
turning inlet orifice in or out (Fig. 5–17). Hold position by tightening 8/32 allen Fig. 5–15 Reassembling Fuel Valve
set screw (Fig. –5–18).
9. Install three alignment studs (Tool Carburetor

C–166–52) in housing (Fig. 5–19). Body
Diaphragm
Screw
O–ring
Inlet Orifice A–01812
Fig. 5–16 Diaphragm Assembly
600, 600D, 610, 611 Loader

10. Note location of vacuum hole
and vent channel hole. Install
parts so that all holes are in
correct alignment (Fig. 5–19).
a. Gasket (Item 1).
Set Screw
b. Inner diaphragm, spacer
cup out (Item 2).
c. Diaphragm spacer,
recessed side out (Item 3).
d. Outer diaphragm,
diaphragm plate in (Item 4).
e. Diaphragm, cover (Item 5)
Gauge (C–161–194)
11. Install three diaphragm screws,
A–01815 A–01816
then remove alignment studs
and install other screws (Fig. Fig. 5–17 Adjust Fuel Valve Fig. 5–18 Adjust Fuel Valve Lever
5–20).
12. Install venturi and fasten with Vacuum

venturi screw (Fig. 5–13, Item Alignment Studs
(C–166–52) Holes
6)

5
13. Install throttle shaft seal and
seal caps. Press caps into 4
position and use a center punch 1
to keep them in place. 3
2
14. Install throttle plate.
Vent
15. Install idle adjustment screw Channel
and spring. Turn the adjusting
screw in until it lightly contacts
the seat, then back the screw
out 1–1/2 to 2 turns. A–01817
Fig. 5–19 Diaphragm Assembly Installation
16. Install new choke spring.
17. Install choke shaft and choke

plate. Alignment
Studs
18. Turn throttle stop screw

clockwise and make
adjustment of throttle for fast
idle.
Screws
A–01818
Fig. 5–20 Install Diaphragm Screws
600, 600D, 610, 611 Loader

5–18 VAPORIZER & PRIMARY REGULATOR SERVICE
Regulator
The vaporizer (Fig. 5–21) consists of a high pressure regulator and vaporizer
combined in a single unit. The high pressure regulator reduces LPG fuel tank
pressure to an even outlet pressure. The vaporizer section changes the liquid fuel
into a gas.
Close the fuel valve at the fuel tank

WARNING before removing the vaporizer.
W–2274–1297
5–19 DISASSEMBLING THE 2

VAPORIZER
3
1. To remove the vaporizer element, 4
put the vaporizer in a vise and Vaporizer
remove the 1–1/4 inch brass nut 5
A–01820
(Fig. 5–27) with a socket wrench.
6 Fig. 5–21 Vaporizer and Regulator
2. Remove the inlet orifice fitting
(Item 11) and aluminum washer 7
(Item 12) from inlet bore. 8
9 Diaphragm
3. Loosen lock nut (Item 3) on 10
adjustment screw (Item 2) and 20

turn screw all the way in to press 19
the inlet valve seat. The valve seat 18
in its normal position will prevent 17
removal of the inlet orifice. 14 16
11 15
4. Turn a 1/4’’–20 screw into inlet
orifice block and remove block
(Item 13).
12 13
NOTE: The spring loaded inlet valve 21
seat must be fully pressed in 22
during this operation to
prevent damage to both the Piston
seat and orifice block.
A–01822
5. Remove pressure adjustment Fig. 5–23 Aligning Piston

screw (Item 2) and spring (Item 4).
6. Remove six diaphragm screws

(Item 5) and the diaphragm cover B–01225
(Item 6). Fig. 5–22 Vaporizer Breakdown
7. Lift rubber diaphragm (Item 9) with assembled piston from bore. Remove
screw (Item 7) that holds diaphragm and holding plate to piston.
8. Reverse vaporizer assembly (Item 15) and remove inlet valve seat, holding
spring and valve cap 16 & 19. Button
9. Remove large O–ring (Item 21) from its groove on outside of vaporizer
housing.
5–20 TO ASSEMBLE THE VAPORIZER
1. Put a new diaphragm (Item 9) over piston (Item 20) and put holding plate
(flange up) on diaphragm. Fasten parts with diaphragm screw but do not Spring
tighten.
2. Check condition of inlet orifice (Item 13). When damaged at orifice shoulder, A–01821
install new. Fig. 5–24 Installing Button and Spring
600, 600D, 610, 611 Loader

3. Put inlet orifice block into its bore
temporarily. This part has a
groove and slides on a dowel pin
in bore to prevent part from being
installed wrong.
4. Put assembled diaphragm and
piston into bore (Fig. 5–23) so that
piston centers over inlet orifice
block without rubbing against it.
5. Make alignment of six screw holes
in diaphragm with holes in
vaporizer top and tighten
diaphragm (Fig. 5–23). Hold
diaphragm and holding plate to
keep them from moving when
tightening screw.
6. Remove assembled diaphragm
and piston and inlet orifice block
from their bores after correct A–01835
alignment has been made. Fig. 5–25 Adjustment of Vaporizer
7. Check inlet valve seat. When neoprene disc is damaged or worn, install a
new, complete unit (Fig. 5–22, Item 14).
8. Put small button on spring and install button end of spring into inlet valve
seat. Install parts into bore (Fig. 5–24).
9. Install assembled diaphragm and piston into bore after installing O–ring on

piston. Put light film of oil over seal for easier installation. Check piston
alignment by looking into inlet orifice bore. Yoke of piston should line up with
inlet orifice bore and six diaphragm holes with the holes in top of vaporizer
(Fig. 5–23).
10. Install cover over diaphragm and fasten it with six screws. Put spring for
adjustment screw (Item 4) into bore through top of cover and install
adjustment screw in lock nut (Item 3).
11. Turn adjustment screw all the way in to press in on the inlet seat.
12. Install a new filter washer on inlet orifice block and insert block in bore using
groove as a guide. Remove 1/4 inch –20 screw from assembled valve (Fig.
5–23).
13. Put a new aluminum washer into orifice bore. Turn inlet orifice retainer into
bore and tighten. Install a new large O–ring into groove on outside of
vaporizer assembly (Item 21).
14. Install a new O–ring in vaporizer head of cooling element. Install fiber washer
and 1–1/4 inch brass nut. Tighten it, using a socket wrench.
5–21 ADJUSTMENT OF VAPORIZER
NOTE: The correct working pressure adjustment for vaporizer is 12 PSI (,84
Kgf/cm@) (gauge pressure).
1. Put assembly in a vise. Connect an air hose which will supply 75 PSI (5,3
Kgf/cm@) to inlet fittings (Fig. 5–25).
2. Connect a 0 to 30 or a 0 to 50 PSI (0–2,1 or 0,3,5 Kfg/cm@) pressure gauge
to outlet.
3. Back off vapor adjustment screw until one or two threads are holding screw
to cover. Put air pressure to unit (Fig. 5–25).
4. Turn pressure adjustments in slowly until 12 PSI (,84 Kfg/cm@) shows on
gauge.
NOTE: When making pressure adjustment, be sure air has been removed
from regulator. Vent out the air by loosening the pressure gauge.
5. When all connections are tightened and adjustment has been made as
above, put soap water over the vent hole in the diaphragm cover. Air will
appear if diaphragm is leaking.
6. After adjustment has been made, tighten lock nut on pressure adjustment
screw. Turn off air pressure and remove gauge and air ling (Fig. 5–25).
600, 600D, 610, 611 Loader

5–22 LP FUEL FILTER LOCK–OFF
The filter lock–off is actuated when ignition key is turned on. A filter element is
located inside the unit. The unit must be removed and disassembled to clean or Tank Lock
install a new element.
Close the fuel valve at the fuel tank

WARNING before removing the filter lock–off.
W–2273–1297
5–23 FUEL FILTER LOCK–OFF DISASSEMBLY

Filter Lock
1. Close hand valve on tank (Fig. 5–26).
B–01968
2. Remove filter assembly from fuel tank (Fig. 5–26). Fig. 5–26 Tank and Filter Lock–Off
NOTE: When cleaning filter remove

complete solenoid first to 12
keep dirt from entering 11
10

solenoid section. 9
6 7 8
5
3. Remove solenoid by putting filter 4
housing in a vise and loosening 3
2
5/8 inch hex brass element (Item 1
1). Remove solenoid section (Item
5).
4. Hold filter housing in a vise and 14 13

use wrench to screw out the filter
inlet (Item 12). It has a 3/4 inch
square nut.
B–01171
Fig. 5–27 Filter Lock–Off Parts
5. Remove filter element and clean any dirt out of filter housing. Clean element
(Fig. 10) by forcing compressed air to it from inside out. Inspect O–ring (Item
11) for damage.
6. Install clean or new filter element inside filter housing (Item 9). Check that
it is correctly seated. Lubricate O–ring with a light mineral oil. Turn filter inlet
completely in by hand then tighten it to 30–40 ft.–lbs. (40,68–54,24 Nm)
torque.
7. Assemble solenoid section to filter housing using a maximum of 18 ft.–lbs.

(24,408 Nm) torque to tighten. Oil O–ring (Item 8) on filter housing to keep
it from being damaged.
600, 600D, 610, 611 Loader

Revised February 80
5–24 ENGINE RECONDITIONING
Clean engine and all parts and
remove all dirt between fins.
5–25 REMOVAL OF ENGINE
1. Disconnect fuel line, wiring and

throttle choke linkage.
2. Remove drive belt.
3. Remove engine fastening bolts.

Use a hoist to remove engine
from loader (Fig. 5–28).
C–02178
Fig. 5–28 Remove Engine From Loader
5–26 REMOVAL OF
ACCESSORIES
Flywheel
Remove the engine oil filter, starter,
hydraulic pump, variable speed

sheave and other installed parts.
(See Variable Speed Sheave
Removal, Page 3–18).
5–27 REMOVAL OF FLYWHEEL
1. Remove the flywheel screen

(Fig. 5–29).
2. Remove the flywheel nut and

B–02584 A–01823
3. Pull flywheel off of taper on
crankshaft. (Use a soft hammer Fig. 5–29 Remove Flywheel Nut & Washer Fig. 5–30 Remove Flywheel
to loosen flywheel (Fig. 5–30).
5–28 REMOVAL OF AIR HOUSING

(Fig. 5–31)
1. Remove cylinder head covers

(Item 1).
2. Remove bolts holding flywheel

housing to lower cylinder
housing (Item 2).
3. Remove bolts holding the

flywheel housing to gear cover
(Item 3).
A–01841
Fig. 5–31 Remove Air Housing
600, 600D, 610, 611 Loader
5–29 REMOVAL OF CARBURETOR AND MANIFOLD
1. Remove manifold nuts (Fig. 5–32).
2. Lift off sections (Fig. 5–32).

5–30 REMOVAL OF CYLINDER HEAD
1. Remove head bolts (Fig. 5–33).
2. Lift heads from engine.
NOTE: Bolts are of different lengths and must be installed according to the
bosses on heads. A–01830
Fig. 5–32 Remove Manifold
5–31 REMOVAL OF GEAR COVER
1. Disconnect governor linkage. Cylinder Head
2. Remove gear cover bolts (Fig.

5–34.)
3. Drive out two dowel pins (Fig.

5–34).
4. Remove cover.

5–32 REMOVAL OF CAMSHAFT
1. Remove three bolts and lock
washers (Fig. 5–35). B–02590 Gear Cover A–01838
Fig. 5–33 Remove Cylinder Head Fig. 5–34 Remove Gear Cover
2. Pull gear from shaft (Fig. 5–35).
NOTE: Camshaft gear has offset
hole to aid in assembly. Camshaft Gear
Gear Gear
Puller
5–33 REMOVAL OF IDLER GEAR
AND SHAFT
1. Remove allen set screw (Fig.
5–36).
2. Remove idler gear and shaft using

a gear puller (Fig. 5–36).
5–34 REMOVAL OF OIL PAN
A–01824 A–01842
1. Turn engine so that it rests on the
cylinder block (Fig. 5–37). Fig. 5–35 Remove Camshaft Gear Fig. 5–36 Remove Idler Gear
2. Remove bolts (Fig. 5–37).

Pipe Plug Oil
5–35 REMOVAL OF OIL PUMP Pump
1. Remove lock nut and pump drive
gear from shaft.
2. Remove groove pipe plug from

bottom of oil pan (Fig. 5–38).
3. Use a 5/32 allen wrench to remove

the lock nut from pipe plug hole Oil Pan
(Fig. 5–38).
4. Remove oil pump. A–01834 Lockscrew A–01831

Fig. 5–37 Remove Oil Pan Fig. 5–38 Remove Oil Pump
600, 600D, 610, 611 Loader

5–36 REMOVAL OF PISTONS AND Connecting
CONNECTING RODS Rod Cap
1. Use a 1/2 inch socket wrench to

loosen and remove hex nuts
from connecting rods (Fig.
5–39).
2. Hit ends of bolts lightly to

release connecting rod cap
(Fig. 5–39).
3. Remove carbon that might

interfere with removal of
pistons from upper end of
cylinders (Fig. 5–40).
4. Turn crankshaft until piston is at B–02582 B–02581

the top of its stroke.
Fig. 5–39 Remove Connecting Rod Caps Fig. 5–40 Remove Carbon From Cylinder Walls
5. Push connecting rod and piston
assembly upward and out
through top of cylinder (Fig.
5–41).

6. Put cap back on connecting rod
to keep them together.
5–37 REMOVAL OF VALVES AND

SEAT INSERTS
1. Remove valve tappet

inspection plate and push the
valve spring together with an
automotive valve lifting tool
(Fig. 5–42). Piston
Assembly
2. Put rag into opening at bottom
of valve chamber so holding
locks do not fall into engine pan. B–02585
Fig. 5–41 Remove Rod and Piston
3. Remove holding locks, seats,

springs, valves and clean in
solvent. Valve
Lifter
NOTE: Mark valves so that they
will be put in same guide Valves
during assembly as they
were when removed.
4. Remove inlet and exhaust

valve inserts when badly worn.
5. Inspect valve guides for wear

and remove when valves stem
clearance is more than .006
inch (,152 mm) (Fig. 5–43). Use
a driver to drive out old guides.
A–01827 A–02543
Fig. 5–42 Remove Valves Fig. 5–43 Check Valve Guides
600, 600D, 610, 611 Loader
5–38 REMOVAL OF CYLINDER BLOCK
1. Remove four holding nuts from cylinder block (Fig. 5–44).
2. LIft off cylinder blocks
5–39 REMOVAL OF CRANKSHAFT
1. Remove six bolts in main bearing plate and remove plate (Fig. 5–45).
B–02588
2. Pull crankshaft from end of housing (Fig. 5–45). Fig. 5–44 Remove Cylinder Block Nuts
5–40 REMOVAL OF CAMSHAFT Crankshaft
1. The camshaft must be pulled from

flywheel end of engine (Fig. 5–46).
Main Bearing
Plate
5–41 REMOVAL OF VALVE TAPPET

1. After camshaft has been taken
out, remove the valve tappets
(Fig. 5–46). B–01843
Fig. 5–45 Remove Crankshaft
5–42 ASSEMBLY OF ENGINE AFTER
RECONDITIONING INSTALLATION
OF VALVE TAPPETS
Camshaft
1. Install valve tappets into proper
position before camshaft is
installed (Fig. 5–46).
NOTE: Valve tappet adjustment
should be made after
cylinder locks have been
installed with engine cold.
The clearance should be .008
inch (,2 mm) for the inlet and
.016 (,4 mm) for the exhaust
valves.
5–43 INSTALLATION OF CAMSHAFT
1. Install spring and plunger in place

at end of camshaft (Fig. 5–46).
2. Push camshaft in thru flywheel

end of engine (Fig. 5–46).
Valve
Tappets
A–01846
Fig. 5–46 Install Tappets and Camshaft
600, 600D, 610, 611 Loader

5–44 INSTALLATION OF CRANKSHAFT Valve
Lifter
Valve
1. Put crankshaft in through end of housing (Fig. 5–45). Stem
2. Install the main bearing plate using the same quantity and thickness gaskets
and shims as when removed. End play must be .002–.004 inch (,05–,10 mm)
when engine is cold.
NOTE: Holes for fastening bolts in the main bearing plate are located so
that the plate will be correctly installed for main bearing lubrication.
3. Install six bolts in the main bearing plate and tighten to 25–30 ft.–lbs.
(33,85–40,67 Nm) torque.
5–45 INSTALLATION OF VALVES AND SEAT INSERTS

A–01827
1. Inspect all valve inserts and install new when necessary. Fig. 5–47 Install Valves
2. Install each valve into same guide from which removed.

3. Install holding locks, seat, spring and valves (Fig. 5–47).
4. Remove rag in opening at bottom of valve chamber.
5. Install inspection plate for valve tappets.
5–46 INSTALLATION OF CYLINDER BLOCKS
1. Install cylinder blocks and fasten each with four holding nuts (Fig. 5–48). B–02588
Fig. 5–48 Install Cylinder Block
2. Tighten nuts to 40–50 ft.–lbs.

(54,23–67,79 Nm) torque.
Compression Ring
5–47 INSTALLATION OF PISTON

RINGS
1. Place open end of piston first and Scraper Ring

spread to fit in groove (Fig. 5–49).
Oil Ring
2. There are four rings to each
piston. The fourth (bottom) ring is
the oil ring, the third is the scraper
ring, second is a compression ring
and the first is a compression ring
(See Fig. 5–50).
3. Install the scraper ring with

scraper edge down (Fig. 5–50).
A–01826 A–01844
Fig. 5–49 Install Piston Rings Fig. 5–50 Piston Ring Sequence
600, 600D, 610, 611 Loader
Revised March 80
5–48 INSTALLATION OF PISTONS
AND CONNECTING RODS Oil Hole
NOTE: Identical numbers are
stamped on the side of
each connecting rod and
its cap. These numbers
must all be on the same
side of connecting rods
when installed in the
engine. Be sure the hole in
the cap is facing toward
the oil spray nozzle (Fig. Ring
5–51). Install new nuts on Oil Spray
Nozzle Compressor
the connecting rod bolts A–01859 B–02586
and tighten to 20–28 Fig. 5–51 Install Rod Caps Fig. 5–52 Using Ring Compressor
ft.–lbs. (27,11–37,96 Nm)
torque.
1. Install piston and connecting

rod assembly in the same bore
as when removed.
NOTE: Oil the pistons, rings,

wrist pins, rod bearings
and cylinder walls before
assembly. Piston

2. Use a ring compressor and
check that ring gaps are 90°
apart around the piston (Fig.
5–52).
3. Check that wide sections of the

piston skirt are toward the
maximum thrust side (Opposite
the crankshaft rotation) (Fig.
5–53).
4. Install connecting rod cap with

bearing half (Fig. 5–51).
Wide Thrust
5. Install rod bearing holding nut Face Opposite Crankshaft
and tighten to 20–28 ft.–lbs. Rotation
(27,11–37,96 Nm) torque.
5–49 INSTALLATION OF OIL

PUMP
1. Install oil pump into crankshaft Connecting Rod

housing (Fig. 5–54). Be sure C–01660
that the seat for the lock screw Fig. 5–53 Piston Position
is in line with the hole for the
screw in the crankshaft
housing.
Pipe Plug Oil
Pump
2. Install the lockscrew into pipe
plug hole (Fig. 5–55). Use a
5/32 inch allen wrench to
tighten lock.
3. Install the grooved pipe plug

from bottom of housing (Fig.
5–55).
5–50 OIL PAN INSTALLATION
1. Install bolts and tighten to 6–9 Oil Pump
ft.–lbs. (8,13–12,2 Nm) torque. B–02580 Lockscrew A–01831
Fig. 5–54 Install Oil Pump Fig. 5–55 Install Pipe Plug
600, 600D, 610, 611 Loader

118 of80
Revised March 214 –5–16– Service Manual
5–51 INSTALLATION OF IDLER
GEAR AND SHAFT
1. Install idler gear and shaft (Fig.

5–56).
2. Check that oil groove and shaft

is in up position, and clearance
between idler gear bearing
(inner race) and shoulder of
shaft is .0015–.0035 inch Idler Gear
(0,0381–0,0889) (Fig. 5–57).
B–02574 B–03139
3. Install the allen set screw (Fig.
5–57A). Fig. 5–56 Install Idler Gear Fig. 5–57 Bearing Adjustment
CAMSHAFT GEAR
1. Put gear on shaft so that holes

are in correct alignment (Fig.
5–58).
NOTE: Be sure the spring and Camshaft

plunger is in place (Fig. Set
5–58). Screw Spring

Gear
Plunger
2. Install three bolts and lock
washers (Fig. 5–58).
5–53 INSTALLATION OF GEAR

COVER
1. Install cover.
2. Install gear cover bolts and two

dowel pins. tighten bolts to
14–18 ft.–lbs. (18,98–24,4 Nm)
torque (Fig. 5–59).
B–02576 B–02393
3. Connect governor linkage rod. Fig. 5–57A Setscrew For Idler Gear Shaft Fig. 5–58 Install Camshaft Gear
CYLINDER HEAD
1. Install cylinder head. Gear

Cover
11 7 5 9
2. Install bolts, putting lengths
according to bosses on cylinder
heads (Fig. 5–60). 15 13
3
NOTE: Oil all cylinder head bolts 1
to protect them from rust. 16
2 17
3. Tighten head bolts in sequence
shown (Fig. 5–60).
14 12
4. Tighten cylinder head bolts to 10 4 6 8
22–24 ft.–lbs. (29,82–32,54
Nm).
B–02578 B–02577
Fig. 5–59 Install Gar Cover Fig. 5–60 Install Cylinder Head
600, 600D, 610, 611 Loader
119 of February
Revised 214 80 –5–17– Service Manual
CARBURETOR AND MANIFOLD
610,611ServiceManual#6556276–WisconsinEngineServiceSection
ASSEMBLY
1. Install manifold assembly on
engine (Fig. 5–61).
2. Install manifold nuts and tighten

to 14–18 ft.–lbs. (18,98–24,4
Nm).
5–56 INSTALLATION OF AIR

HOUSING
1. Install bolts for holding the

flywheel housing to gear cover.
A–01830
2. Install bolts for holding flywheel
housing to lower cylinder Fig. 5–61 Install Manifold Assembly
covers (Fig. 5–62).
3. Install cylinder head covers

(Fig. 5–62).

FLYWHEEL
1. Push flywheel on taper of

crankshaft. Check that
woodruff key is in position on
shaft and is in alignment with
groove in flywheel bore (Fig.
5–63).
A–01841
2. Install flywheel nut and washer
and tighten to 40–60 ft.–lbs. Fig. 5–62 Install Air Housing
(54,23–81,34 Nm) torque.
3. Install flywheel screen (Fig.

5–63).
ACCESSORIES
Install engine oil filter, starter,
hydraulic pump variable speed
sheave and other parts.
B–02584
Fig. 5–63 Install Flywheel
600, 600D, 610, 611 Loader

120 of 21480
DEUTZ ENGINE SERVICE
Paragraph Page
Number Number
ASSEMBLE THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 6–6
CHECKS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 6–1
COMPRESSION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2.2 6–2
CONNECTING ROD BEARING CHECK
AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.10 6–24
COOLING AIR BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.16 6–29
CRANKCASE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.3 6–17
CRANKSHAFT AND BEARING CHECKS
AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.5 6–19
CRANKSHAFT CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.1 6–17
CRANKSHAFT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . 6–5.2 6–17
CYLINDER CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.12 6–25
CYLINDER HEAD REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.14 6–26
ENGINE RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 6–4
FRONT COVER CHECK AND REPAIR
OF ENGINE GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.8 6–20
FUEL INJECTION NOZZLE REMOVAL

AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.17 6–30
FUEL INJECTION PUMP CHECK . . . . . . . . . . . . . . . . . . . . . . . 6–2.4 6–2
FUEL SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2.3 6–2
GENERAL ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 6–31 DEUTZ ENGINE
SERVICE
GOVERNOR CHECK AND REPAIR . . . . . . . . . . . . . . . . . . . . . 6–5.9 6–23
MAIN BEARING CHECK AND INSTALLATION . . . . . . . . . . . . 6–5.4 6–18
NEW GEAR STARTER RING ON
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.7 6–20
OIL PUMP CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.6 6–20
PISTON CHECK AND MEASURING . . . . . . . . . . . . . . . . . . . . . 6–5.13 6–25
PISTON PIN BUSHING CHECK
AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.11 6–25
ROCKER ARM REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5.15 6–29
START OF FUEL INJECTION ADJUSTMENT . . . . . . . . . . . . 6–2.6 6–3
T.D.C. AND START OF FUEL INJECTION . . . . . . . . . . . . . . . . 6–2.5 6–3
TIGHTENING BOLTS AND STUDS . . . . . . . . . . . . . . . . . . . . . . 6–1 6–1
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 6–2.1 6–1
600, 600D, 610, 611 Loader

600, 600D, 610, 611 Loader

6 DEUTZ (ENGINE RECONDITIONING)
6–1 INSTRUCTIONS FOR TIGHTENING BOLTS AND STUDS
NOTE: All fasteners must first be tightened lightly to 14–21 ft.–lbs. (1.9–2.9
m*Kgf) torque. Tighten in sequence until correct adjustment has
been made. Before assembling bolts and studs put oil on threads
and surfaces of head or nut.
1. First tightening can be done using a socket wrench or box end wrench (Fig.
6–1 A).
2. Tightening must be done in correct sequence. A special tool (Deutz number

4689) can be used to check angle of turn when tightening (Fig. 6–1 B). N–15889 A B N–15890
Fig. 6–1 Initial Tightening
3. Figure 6–2 shows angle of rotation in degrees.
NOTE: Drill a 3/8 inch (9,5 mm) hole
in location shown in figure
6–2a to let water out of starter
before it goes into main
housing. Water in the starter
causes circuit failure.
6–2 CHECK AND ADJUSTMENTS
These adjustments can be made
separately, usually after an engine has

been reconditioned.
6–2.1Adjustment of Valve Drill
Clearance Here
NOTE: The engine must be cold. N–15891 C–01927
1. Loosen and remove bolts Fig. 6–2 Angle Of Rotation Fig. 6–2a Hole Location
fastening cylinder head covers
(Fig 6–2).
2. Turn crankshaft so that valves of

number one cylinder (on flywheel
side) are in balance (both valves
closed) (Fig. 6–4).
3. Mark position of overlap of

number one cylinder on edge of
V–belt pulley in alignment with
line marked on engine housing
(Fig. 6–5).
4. Turn crankshaft 360 degrees

clockwise. N–15892 N–15893
Fig. 6–3 Removing Head Covers Fig. 6–4 Both Valves Closes
5. Check valves of first cylinder and
make adjustment when needed.
Loosen lock nut on set screw of
rocker arm. Make adjustment of
set screws so feeler gauge has
light resistance when passing
between rocker arm and valve.
Valve clearance for inlet and
exhaust is .006 inches (0,15
mm).
NOTE: After a cylinder unit repair
has been done, valve
clearance must be set on
high side, .059 inches (1,5
mm).
6. Tighten lock nut without turning N–15894
set screws. Fig. 6–5 Marking Position of Overlap Fig. 6–6 Cylinder Head Cover Gasket
600, 600D, 610, 611 Loader
7. Turn crankshaft through 540 degrees (1–1/2 turns). Make adjustment of
valves on second cylinder.
8. When installing cylinder head covers, make sure gasket is in good condition.
Make sure packing rings are placed under holddown nuts (Fig. 6–6).
6–2.2 Compression Check

Use a compression tester (Fig. 6–7). Compression must be 385–450 PSI
(2564,57–3102,75 kPa).
Before checking, run engine at full speed so lubricating oil can seal combustion
chambers. For test, the speed control lever must be back to fuel shut–off position.
N–15895
Install adapter of compression tester in place of glow plug (Fig. 6–8).
Fig. 6–7 Checking Compression
The indication must not be lower than
minimum specified values. The
pressure of both cylinders must be
uniform 385–450 PSI
(2564,57–3102,75 kPa).
NOTE: Before starting repair, make
an inspection record to
include results of
compression check. Also list
engine wear and new parts.
6–2.3 Checking Fuel System

A tank filled with fuel is required for this
test. It must be higher than injection
pump when engine has been removed
from loader. N–15896 N–15897
1. Check fuel filter to make sure it Fig. 6–8 Glow Plug Fig. 6–9 Filter Outlet
is working. Check fuel flow after
disconnecting line from filter
outlet (Fig. 6–9).
2. Loosen air vent screw in fuel
injection pump. Let fuel to pump
flow until it is free of air (Fig.
6–10).
3. Remove cover for injection
nozzle holder. Remove air
4. Loosen fuel line connection at
nozzle holder (Fig. 6–12). Start
engine or turn it by hand and
check for fuel flow.
N–15898 N–15899
5. Assemble and tighten all Fig. 6–10 Loosening Air Vent Screw Fig. 6–11 Removing Air Housing
connections.
6–2.4 Checking Fuel Injection

Pump
When pump is installed, only
tightness of pressure release valves
and pumping elements can be
checked.
1. Remove air housing (Fig. 6–11),
and disconnect fuel lines (Fig.
6–12).
2. Fasten pressure indicators
(Deutz number 3202) to
respective fuel lines on fuel
injection pump. N–15900 N–15901
Fig. 6–12 Loosening Fuel Lines Fig. 6–13 Press Excess Fuel Button
3. Press excess fuel button (Fig.
6–13).
600, 600D, 610, 611 Loader
Revised February 80
4. Turn crankshaft by engaging starter. Loosen plug and let out air pressure.
Tighten the plug (Fig. 6–14).
5. To check a pressure relief valve, turn engine to generate a pressure to 2130

PSI (149.7 Kgf/cm2) and observe pressure gauge. The pressure must not
decrease to less than 1990 PSI (139.9 Kgf/cm2) within one minute.
6. To check pump element, turn crankshaft about five revolutions. Pressure

should not be less than 4267 PSI (299 Kgf/cm2).
7. Remove pressure indicator.
8. Connect fuel lines first locate tapes on adapter and turn on union nut (Fig.
6–15). N–15902
Fig. 6–14 Releasing Air
9. Install air housing.
6–2.5 To Find top Dead Center And Start Of Fuel Injection
1. Check valve clearance and correct.
2. Turn crankshaft so piston and number one cylinder are at point of maximum
compression (Firing Point) before TDC.
3. Use a screwdriver press down on valve of number one cylinder and put a
piece of 5 to 6 millimeter (1/4 inch) steel plate between valve stem and rocker

(Fig. 6–16).
4. Turn crankshaft clockwise until piston makes contact with proper valve.
5. Mark position of crankshaft on edge of V–belt pulley, in line with cast N–15903
dead–center mark on crankcase (Fig. 6–17). Fig. 6–15 Reconnecting Fuel Lines
6. Remove piece of steel plate. Turn

crankshaft about 90°. Install piece
of steel plate between same valve
stem and rocker. Rotate
crankshaft counterclockwise until
piston again makes contact. Mark
second position.
7. Remove piece of steel plate and

install cylinder head covers.
8. With a flexible steel rule measure

and mark half way position
between two marks (6–18).
B–02201 PI–02052
9. Using a flexible steel rule from TDC Fig. 6–16 Determining Top Dead Center Fig. 6–17 Marking Crankshaft Position
indicator, mark distance to start of
delivery. Mark in clockwise
direction of rotation. Start of
delivery is 150 PSI (10.6 Kgf/cm2)
(Fig. 6–19).
6–2.6 Adjustment Of Start Of Fuel

Injection
Put a mark on edge of V–belt pulley at
point which fuel injection starts.
1. Remove air housing and
disconnect fuel injection lines (Fig.
6–11.)
B–02205 PI–01983
Fig. 6–18 Marking Half–Way Position Fig. 6–19 Marking Start Of Delivery
600, 600D, 610, 611 Loader
2. With engine located on repair
bench, connect a tank of diesel fuel
to fuel filter inlet (Fig. 6–20). (Tank
must be higher than inlet.)
3. Turn engine to remove air from fuel

supply system (use tool Deutz
number 320°) (Fig. 6–21). then
return first cylinder to the firing
order before TDC.
4. Turn crankshaft slowly until level of

fuel can be seen in capillary tubes.
N–15904 PI–02070
NOTE: At the same time, the
start–of–injection indicator Fig. 6–20 Providing Fuel to Filter Fig. 6–21 Bleeding Air From System
on the V–belt pulley must be
in line with the dead–center
mark on the crankcase cover
(Fig. 6–22).
5. For adjustment of the timing of the

start–of–injection, remove the fuel
injection pump. Increase or
decrease the number of gaskets
between the pump and cover (Fig.
6–23).

NOTE: One gasket 0.3 mm (.012
inches) thick corresponds
to about 2° of crankshaft
turn. Fuel injection will be PI–02069 PI–02068
advanced by removing Fig. 6–22 Alignedwith Dead–Center Mark Fig. 6–23 Adding or Deleting Shims
gaskets and retarded by
adding gaskets. One gasket
must be left to act as a seal.
6. Before installing fuel injection

pump, put fork of control lever
into alignment with groove in
7. Install and secure injection pump

with ball head of control rod
facing control lever.
8. Check start of fuel injection and

correct when needed.
PI–02044 PI–01998
9. Remove capillary tube. Fig. 6–24 Aligning Fork with Recess Fig. 6–25 Lock Down the Union Nuts
10. Connect fuel lines. In each case locate cone end of line and connecting stub
and run union nut down finger tight, to make sure that cone is correctly
seated. Tighten the union nuts (Fig. 6–25).
6–3 ENGINE RECONDITIONING

Remove the following parts:
Starter, generator, fuel filter with fuel line to injection pump, induction pipe, exhaust
manifold, air housing, oil cooler, side cover plates, leak off pipe, fuel injection pipe
and cooling air blower.
NOTE: To keep out foreign material put caps on connecting ends and
delivery opening of injection pump (Fig. 6–26). N–15906
Fig. 6–26 Keep Out Foreign Matter
600, 600D, 610, 611 Loader

1. Remove injectors (Fig. 6–27).
2. Loosen cylinder head holddown

bolts in diagonal sequence (Fig.
6–28), in steps. Remove
cylinder head complete with
studs and push rods protective
tubes. (Use special wrench for
holddown bolts, Deutz number
1310–02.)
3. Remove lower crankcase

cover. Loosen and remove
connecting rod bolts (Fig. N–15907
6–29).
Fig. 6–27 Removing Injectors Fig. 6–28 Removing Cylinder Head
4. Lift up bearing cap with a bar.
Pull cylinder with piston and
connecting rod, from crankcase
(Fig. 6–30).
NOTE: The bearing must be

protected against damage
and must be marked on
the back for correct
assembly.

5. Remove injection pump.
6. Remove V–belt pulley and

flywheel.
N–15908 N–15909
7. Remove front cover Loosen Fig. 6–29 Removing the Big–End Bolts Fig. 6–30 Withdraw the Cylinder
only bolts around outside edge.
8. Remove rear end shield, using

tool for removing end shield on
flywheel side (Deutz number
4683) (Fig. 6–31).
9. Remove loose governor plate

and fly weights from governor.
Push the ball bearing with gear
wheel and governor shaft out of
crankcase (Fig. 6–32).
10. Put engine on it’s cylinder head

contacting surface, while
holding the loose camshaft. B–02202 B–02200
Remove the camshaft.
Fig. 6–31 Removing the End Shield Fig. 6–32 Removing the Governor
11. Remove crankshaft gear
wheel. Remove bolt holding
center bearing block (Fig.
6–33).
12. Remove crankshaft.
13. Remove bolt holding lube oil

pump. Bolt is reached from
underside of crankcase (Fig.
6–34).
N–15910 N–15911
Fig. 6–33 Remove Center Bearing Block Fig. 6–34 Remove Lube Oil Pump Screw
600, 600D, 610, 611 Loader
14. Turn free pump so connecting
end is opposite groove in
bearing bore, then remove
pump (Fig. 6–35).
15. Remove loose tappets.
16. Remove following parts from

crankcase; retainers for seal
rings of push rod cover, oil
pressure switch, crankcase
vent and lube oil pressure N–15912 N–15913
control valve.
Fig. 6–35 Removing the Oil Pump Fig. 6–36 Remove the Slotted Plugs
17. Remove plugs with groove for

camshaft lubrication, after
which crankcase is ready for
cleaning (Fig. 6–36).
6–4 TO ASSEMBLE THE ENGINE

All parts of disassembled engine
must be cleaned and checked for
damage. (See Inspection And

Repair.) the crankshaft and camshaft
bearing bushing must be pushed into
engine housing.
N–15914 N–15915
Fig. 6–37 Lock the Sealing Plug Fig. 6–38 Oil Pressure Switch
1. Use sealing plug for the
camshaft oil way. Put it in even
and hit with a center punch to
lock (Fig. 6–37).
2. Install oil pressure switch (Fig.

6–38).
3. Install crankcase breather (Fig.

6–39).
4. Install breather housing using a

new O–ring (Fig. 6–40). N–15916 N–15917
Fig. 6–39 Install the Crankcase Breather Fig. 6–40 Install Breather Housing
5. Install breather tube to

crankcase (Fig. 6–41).
6. Install oil pressure relief valve in

housing. Use new gasket (Fig.
6–42).
N–15918 PI–02067
Fig. 6–41 Installing Breather Tube Fig. 6–42 Install Oil Pressure Relief Valve
600, 600D, 610, 611 Loader

7. Check that same number is
marked on housing and bearing
cap and that both heavy duty
retainer studs are available for
8. Install bearing in housing and

bearing cap. Check locating pin
(Fig. 6–44).
9. Put motor oil on bearing and put

bearing housing on middle main
bearing journal.
PI–02059 N–15920
10. Install bolt and steel washers
(Fig. 6–45). Tighten and lock Fig. 6–43 Check Marks Fig. 6–44 Locating Pin
down bolts according to
fastener tightening instructions.
Refer to table for angles of turn
to which screws should be
tightened.
11. Put thrustwasher on front

crankshaft bearing with
lubricating oil ways facing crank
and tab in groove in the

crankcase. Put grease on
washer to hold it in position (Fig.
6–46).
PI–01988 PI–01989
12. Put motor oil on front crankshaft
bearing. Fig. 6–45 Installing Cap Screws Fig. 6–46 Installing Thrust Washer
13. Install crankshaft into

crankcase with short end of
shaft facing timing gear.
14. Put bearing housing so hole is

in alignment with stud. Install
stud and steel washer (Fig.
6–47). Tighten it according to
tightening procedures.
15. Put thrustwasher on end shield.

Put grease on thrustwasher.
The tab of water will drop into
recess in end shield (Fig. 6–49).
PI–01993 N–15921
16. Put oil on the crankshaft Fig. 6–47 Positioning Bearing Housing Fig. 6–48 Positioning Thrust Washer
bearing and end shield.
17. Install end shield, using a new

gasket (Fig. 6–49).
18. Measure end clearance of

crankshaft. It must be
.008–.016 inches (0,200–0,400
mm). When clearance is more,
the end shield must be
removed. Remove bolts, then
withdraw end shield with puller
(Fig. 6–50). Fit shims (.006
[0,150 mm thick]) under end
shield for correct end
clearance.
PI–01996 B–02202
Fig. 6–49 Mounting the End Shield Fig. 6–50 Pull the End Shield
600, 600D, 610, 611 Loader
19. Install lube oil pump, put tube
end and groove in bearing bore
(Fig. 6–51).
20. Put oil pump so hole for locking

screw is in alignment. Install
and tighten bolt (Fig. 6–52).
21. Put on crankshaft gear wheel.

Tighten and lock down (Fig.
6–53).
22. Put oil on tappets and install in

crankcase (Fig. 6–54). N–15922 N–15923
Fig. 6–51 Install the Lube Oil Pump Fig. 6–52 Locking Pump in Place
23. Install camshaft. Install
thrustwasher to front camshaft
bearing (Fig. 6–55). Put oil on
bearing areas. Install camshaft
end in engine housing.
NOTE: The camshaft gear wheel

must be installed so tooth
marked with a dot
engages in groove marked
with two dots on
crankshaft gear wheel.

The other gap marked with
two dots should be in
direction of governor
bearing bore (Fig. 6–56).
B–02199 N–15924
24. Turn engine upside down while Fig. 6–53 Mount the Crankshaft Gearwheel Fig. 6–54 Installing Tappets
holding loose camshaft.
25. Install assembled centralfugal

governor. Force governor shaft
ball bearing into its seating
position in engine housing.
Install governor shaft. Install
retainer washer with its offset
side facing the bearing. Install
and tighten fastening screw
(Fig. 6–57)
B–02198 N–15925
NOTE: Make sure gears are Fig. 6–55 Install Camshaft Thrust Washers Fig. 6–56 Correct Engagement
correctly engaged. The
tooth mark with a dot on
governor and camshaft
gear wheels must engage
in same gaps marked with
two dots on crankshaft
gear wheel (Fig. 6–58). Put
fly weights in guide plate
and assemble governor
dish (Fig. 6–59).
N–15926 PI–01994
Fig. 6–57 Install the Governor Shaft Fig. 6–58 Correct Engagement
600, 600D, 610, 611 Loader

Push governor plate in seat
location and measure distance
from front face of plate to wall
(3–2/5 inch [85,7 mm]) (Fig.
6–60). When distance is not
within correct rage, make
correction with shims.
26. Install distributor housing for oil

filter and turn it until locating tab
engages in slot in engine PI–01995 N–15927
housing (Fig. 6–61). Install Fig. 6–59 Assemble the Governor Fig. 6–60 Locate the Governor Dish
compression spring for
distributor housing in front
cover assembly (Fig. 6–62).
Check that two locating pins are
installed into front caliper (Fig.
6–63).
27. Install anew gasket to front

cover.

28. Measure camshaft end
clearance. The correct
dimension is .005–.024 inch PI–01986 PI–01985
(0,15–0,6 mm) (Fig. 6–64 &
6–65). Fig. 6–61 Insert Distributor Housing for Oil Filter Fig. 6–62 Insert the Compression Spring
29. Install front cover assembly and

fasten it with seventeen bolts
(Fig. 6–66).
PI–01990 PI–01987
Fig. 6–63 Install the Locating Pins Fig. 6–64 Camshaft End Clearance
PI–02057 PI–02054
Fig. 6–65 Camshaft End Clearance Fig. 6–66 Install the Front Cover
600, 600D, 610, 611 Loader
NOTE: Check different lengths of
bolts. The longest bolt
should be installed in hole
below oil filter location
(Fig. 6–67).
30. Install V–belt sheave.

Check that heavy fastening
sleeve for locating V–belt pulley
is assembled (Fig. 6–68).
Put V–belt sheave in position
and install tightening bolt with N–15928 N–15929
steel washer. Tighten and lock Fig. 6–67 Longest Screw Location Fig. 6–68 Clamping Sleeve
down bolt following tightening
instructions (Fig. 6–69).
31. Line fork of control lever with

recess in engine housing (Fig.
6–70).
Install fuel injection pump with
ball head of control rod facing
control lever and fasten.

Measure distance from top face
of engine housing to the base
circle of the cam. (See
SPECIFICATIONS.) Add
gaskets when necessary (Fig. N–15930 N–15931
6–71 & 6–72).
Fig. 6–69 Installing The V–Belt Pulley Fig. 6–70 Aligning Fork with Recess
32. Push a new bearing bushing

into flange bearing (Hydraulic
pump drive) (Fig. 6–73).
Install a new seal ring with lip
toward bushing and press it into
position by putting even
pressure around circumference
(Fig. 6–74). Install a new gasket
to flange and use grease to hold
it in position.
PI–02043 N–15932
Fig. 6–71 Taking Measurement Fig. 6–72 Installing Injector Pump
N–15933 N–15934
Fig. 6–73 Install Bushing and Seal Fig. 6–74 Install a New Gasket
600, 600D, 610, 611 Loader

Install flange bearing with oil
return hole at bottom. Install and
tighten holding bolt (Fig. 6–75).
33. Install flywheel. Install

fastening bolts with steel
washers. Tighten 60° + 30° and
lock the fastening bolts (Fig.
6–76).
N–15935 N–15936
Fig. 6–75 Mount the Flange Bearing Fig. 6–76 Mount the Flywheel
34. Use snap rings when

assembling piston pins into
pistons (Fig. 6–77).
35. Install piston onto connecting

rod so tip of gas guiding
channel in piston crown side of
big end both face upward (Fig.

6–78).
PI–02053 N–15937
Fig. 6–77 Assembling Piston Pin Fig. 6–78 Mount Piston on Rod
Put oil on piston pin and push it

into connecting rod busing so it
is against installed snap ring
(Fig. 6–79). Install other snap
ring.
36. Put oil on working surfaces of

cylinder. Make sure ring gaps
are not in line on piston. Use a
ring compressor (Deutz
number 1–410–05) (Fig. 6–80).
N–15938 N–15939
Fig. 6–79 Installing Piston Pin Fig. 6–80 Installing Piston
NOTE: Line piston with

connecting rods so that
low side of big end is
toward side of cylinder
barrel which has four not
even cooling fins (Fig.
6–81).
37. Assemble .08 inches (20,2 mm)

thick shims to each cylinder.
Put grease on shims to hold
them in position (Fig. 6–82).
PI–02056 N–15940
Fig. 6–81 Aligning Piston Fig. 6–82 Installing Shims
600, 600D, 610, 611 Loader
38. Put grease on new rubber
O–ring and install it in groove at
base of cylinder (Fig. 6–83).
39. Install bearing in connecting rod

big end. Put oil on bearing.
NOTE: The correct size bearing

must be used.
40. Position crankcase on starter

side. N–15941 PI–02055
Fig. 6–83 Installing O–ring Fig. 6–84 Installing Cylinder Assembly
41. Install piston cylinder and

connecting rod assembly in
crankcase. Check that
connecting rods are assembled
with identification numbers in
correct position. The four not
even fins of cylinder and low
junction point of connecting rod
must be toward tappet holes
(Fig. 6–84).

42. Put connecting rod with
assembled bearing on crankpin
(Fig. 6–85).
N–15942 N–15943
Fig. 6–85 Place Rod End on Crankpin Fig. 6–86 Installing Connecting Rod Caps
43. Assemble connecting rod cap
with bearing. Check that
identification numbers are in
correct position (Fig. 6–86).
NOTE: Use new connecting rod

bolts. they must be
tightened 30° + 60° and
fastened down.
44. Install lower crankcase cover

and check that oil plug is in
correct position. The gasket for
cover must be new (Fig. 6–87).
N–15944 PI–02064
45. Put engine with cylinders in
vertical position. Fig. 6–87 Install Lower Crankcase Cover Fig. 6–88 Cylinder Head Stud Length
46. Install cylinder head assembly

and loosely install bolts (Fig.
6–88).
47. Cover the intake opening.
48. Make alignment of cylinder

heads to flange faces for
exhaust manifold (Fig. 6–89).
49. Tighten 30° + 60° + 60° and

fasten down cylinder head
studs from corner to corner
(Fig. 6–90).
PI–02047 N–15945
Fig. 6–89 Align the Cylinder Heads Fig. 6–90 Tightening Down Head Bolts
600, 600D, 610, 611 Loader

50. Check width of gap between
crown of piston and face of
cylinder head.
When piston is in top dead
center position, install a piece of
.078 inch (2 mm diameter) lead
wire in opening for injection
nozzle holder (Fig. 6–91). the
lead wire must extend exactly
across full diameter of piston
(Fig. 6–92).
51. Turn crankshaft through 360° of

rotation. N–15946 N–15947
Fig. 6–91 Inserting Lead Wire Fig. 6–92 Lead Wire
Remove lead wire and measure
thickness at greatest
compressed point. Correct
distance from face of cylinder
head to crown of piston is
.035–.043 inches (.9–1.1 mm)
(Fig. 6–93).
When distance is less than
limits it must be corrected by
placing shims between cylinder
barrel and crankcase. A
distance over maximum can be

corrected by removing a shim
without removing cylinder.
Remove only the cylinder head.
the shim can then be cut
through and removed (Fig. N–15948 N–15949
6–94).
Fig. 6–93 Gauging Lead Wire Thickness Fig. 6–94 Removing shim
52. Install new seals for protective
tubes with beveled edges
downward in crankcase.
Loosely install clamping plates
(Fig. 6–91).
53. Install protective tubes fitting

with new seals. the bevel edge
of new seal must be toward
bearing surface under head of
protective tube (Fig. 6–96).
54. Tightening fastening plates that

retains lower protective tube
seal rings (Fig. 6–95).
PI–02037 PI–02038
55. Install push rods. Fig. 6–95 Install the Clamping Plates Fig. 6–96 Install the Protective Tubes
56. Loosen valve adjustment bolts

in rocker arm assembly.
57. Install rocker.
58. Install a bearing busing for each

rocker and install rocker.
Tighten bolt tight and fasten
(Fig. 6–97).
59. Make valve clearance

adjustments.
60. Fasten cylinder head covers

using a new packing and a new N–15950 N–15951
gasket (Fig. 6–98). Fig. 6–97 Rocker Screws Fig. 6–98 Attach Cylinder Head Cover
600, 600D, 610, 611 Loader
61. With a brush apply graphite
grease to nozzle holder
threads. Turn nozzle holder,
fitted with a new gasket, finger
tight in cylinder head. It must
not be fastened down until fuel
injection lines have been
connected (Fig. 6–99).
62. With a brush cover threads of

heater plug with a graphite
grease. Turn in heater plug.
Connect electric supply wire
N–15952 N–15953
(Fig. 6–100).
Fig. 6–99 Loosely Fit Nozzle Holders Fig. 6–100 Screw in the Heater Plug
63. Install induction line, using new

Fasten induction line on first

cylinder with a single, groove
bolt (Fig. 6–102).
64. Fasten baffle between

cylinders on exhaust side (Fig.

6–103).
65. Install new gaskets for exhaust

N–15954 N–15955
manifolds and install manifolds.
The holddown nuts must be Fig. 6–101 Installing the Induction Pipe Fig. 6–102 Securing Induction Pipe
brass and washers must be
used (Fig. 6–104).
66. Install end plates next to

cylinders (Fig. 6–105).
67. Install cooling air blower and

fasten with three bolts (Fig.
6–106).
N–15956 N–15957
Fig. 6–103 Installing Baffle Fig. 6–104 Install Manifold
N–15958 PI–02051
Fig. 6–105 Install the End Plates Fig. 6–106 Mount the Blower
600, 600D, 610, 611 Loader

68. Install generator.
The sleeve for installing

generator must be installed with
shoulder end in the cooling air
blower(Fig. 6–107).
Install generator and install

shims to close gaps between
sleeves and grooved arm of
generator. N–15959 N–15960
Fig. 6–107 Install Spacer Sleeve Fig. 6–108 Check V–Belt Pulley Alignment
Check V–belt sheave for

alignment (Fig. 6–108).
Correct any alignment by

changing over shims between
generator and bearing points
on cooling air blower (Fig.
6–109).

Check that bushing is in place
before installing bolts in N–15961 N–15962
grooved adjustment straps
(Fig. 6–110). To install other Fig. 6–109 Spacing Shims Fig. 6–110 Installing Spacer and Screw
type generator see (Fig.
6–111).
1
Correct belt tension is about 5/8

inch (15 mm) play on the
longest belt length (Fig. 6–112).
69. Fasten fuel filter to crankcase

on flywheel side (Fig. 6–113).
2
B–01246
Fig. 6–111 Alternator Mounting
N–15963 N–15964
Fig. 6–112 Belt Tension Fig. 6–113 Attaching Fuel Filter
600, 600D, 610, 611 Loader
70. Install fuel line between delivery
filter and injection pump. Use
new gasket on both sides of
special fitting (Fig. 6–114).
71. Use clip to fasten fuel line to

front cover (Fig. 6–115).
72. Make correct adjustment of

delivery of injection pump (See
page 6–3).
N–15965 N–15966
73. Install fuel injection lines. The Fig. 6–114 Install the Fuel Line Fig. 6–115 Secure the Fuel Line
tapered ends must first be in
place and union nuts tightened
by hand. Check that tapered
ends are correctly in seat.
Fasten down union nuts (Fig.
6–116)
74. Fasten fuel injection line clip

above cooling air blower. Make
sure vibration rubbers are in
good condition.

N–15967 N–16046
Fig. 6–116 Lock Down the Union Nuts Fig. 6–117 Tighten the Nozzle Holder
NOTE: The fuel injection lines

must be installed so they
are clear of all wear areas.
75. Tighten nozzle holder using a

wrench (Deutz number 4605)
(Fig. 6–117).
76. Install leak–off line. Install a

new gasket on both sides of
special fittings (Fig. 6–118).
N–15968 N–15969
Put oil cooler through end plate Fig. 6–118 Install the Leak–Off Pipe Fig. 6–119 Install the Oil Cooler
on flywheel side (Fig. 6–119).
Put a hollow bolt in each end of

tubular oil cooler. Install a new
gasket on each side of special
fittings (Fig. 6–120). Slip two
holders for oil cooler on cylinder
head studs. Check that they are
correctly located (Fig. 6–121).
N–15970 N–15971
Fig. 6–120 Securing Cooler Ends Fig. 6–121 Oil Cooler Holders
600, 600D, 610, 611 Loader

Fasten oil cooler to holders.
Check that they are clear of
wear areas (Fig. 6–122).
77. Install air housing and fasten it
in position (Fig. 6–123).
NOTE: Check that fuel injection

lines are clear of housing.
78. Install starter (Fig. 6–124).
79. Fill crankcase to proper level

with correct grade of motor oil. PI–02050 N–15972
Fig. 6–122 Secure the Oil Cooler Fig. 6–123 Mount the Air Housing
6–5 INSPECTION AND REPAIR
6–5.1 Checking The Crankshaft
1. Disassemble crankshaft
bearing housing.
2. Check crankshaft for cracks. If

any are found, install new
crankshaft.
3. Test journal surfaces for

hardness with a scleroscope
(Fig. 6–125).
4. Measure crankshaft points for N–15973 N–15974

tolerances as in (Fig. 6–126 &
6–127). Check for Fig. 6–124 Attach the Starter Fig. 6–125 Test the Journal Hardness
out–of–round with a dial
indicator gauge (Fig. 6–128).
5. Check working surfaces for

radial seal ring on journal at
flywheel end to determine if it is
good.
6–5.2 Reconditioning Crankshaft
NOTE: Mark and remove

crankshaft counterweights
when assembly uses
same type of bolts and N–15975 N–15976
steel washers. Tighten
and fasten down bolts. Fig. 6–126 Measuring Points Fig. 6–127 Micrometer Readings
1. Grinding
The crankshaft bearings can be

taken down to .020, .040 (5,80, 10,16
mm) undersize.
6–5.3 Checking Crankcase
1. Check crankcase that it is

clean. Check lubrication oil
ways which can be cleaned out
with air.
2. Inspect crankcase for cracks

(Fig. 6–129). N–15977 N–15978
Fig. 6–128 Check Bearings for Out–Of–Round Fig. 6–129 Inspecting Crankcase for Cracks
600, 600D, 610, 611 Loader
3. Clean all tapped holes (Fig.
6–130).
4. Check main bearing bores. The
bearing bushings fitted for
crankshaft and camshaft must
be seated. The unlined bores
must be free of wear (Fig.
6–131).
5. Check contact surfaces for
cylinders. They must be flat and
free from damage (Fig. 6–132).
NOTE: Contacting surfaces can N–15979 N–15980

be machined.
Fig. 6–130 Clean All Tapped Holes Fig. 6–131 Check Bearing Bores
6–5.4 Checking And Installing
Main Bearing
Main bearing are of thin type. Do not
recondition them. Various diameter
bushings and housing that are
supplied are .020, .040 (5,08, 10,16
mm).
1. Measure bearing bushings
fitted into crankcase and back
end cover.

2. Check bore of lower half of
crankshaft bearing.
Bolt cap to lower half of bearing.
Make sure identification marks N–15981 N–15982
are correct. Tighten 30° + 60°
and fasten down bolts (Fig. Fig. 6–132 Check Cylinder Contact Surface Fig. 6–133 Bolt Cap to Bearing
6–134).
3. Measure assembled bearing
housing.
Install two shelf halves (Fig.
6–134). Check assembly.
Check tolerance of bearings.
When measurements are
within specific tolerance range
or up to 0,2 mm (.007 inches)
beyond it, the bearing housing
can be used.
4. Install measured bearing
halves in correct housing.
Remove bearing bushings N–15983
requiring replacement and Fig. 6–134 Install Two Shell Halves Fig. 6–135 Extracting Bearing Bushings
install new ones (use tool,
Deutz number 4679).
To remove bearing bushings
from crankcase, fasten the tool
with pressure plate and full
length tension bolt together with
guide sleeve and thrust sleeve
(Fig. 6–135). Install (from
outside) the extractor bell with
handle in nut (Fig. 6–136).
Remove bearing bushing.
When installing bearing
bushing, check that oil hole is
correct position with crankcase
bore (Fig. 6–137).
PI–02066
Fig. 6–136 Mount the Extractor Ball Fig. 6–137 Oilhole Alignment
600, 600D, 610, 611 Loader

Install bearing bushing. Put it on
guide sleeve of tool in front of
pressure plate. The thrust
sleeve then has to fit bushing
into crankcase bore (Fig.
6–138).
Install bearing housing so that it
extends out of crankcase
surface (See Specifications,
page 6–33) (Fig. 6–138).
5. Use driver to force out seal
rings before removing bearing
bushing from rear end cover PI–02066
(Fig. 6–139). Fig. 6–138 Install Bearing into Crankcase
6. When installing bearing
bushing check oil hole for
correct position with end shield
bore. Install bearing bushing so
that outer end (seal ring) is even
with end of cover bore (Fig.
6–140).
7. Put seal with lip facing bearing,

use even pressure around
circumference.

6–5.5 Checking and Installing
Camshaft and Bearings
1. Inspect camshaft, check
bearing and cam faces. Check
camshaft gear wheel for tooth N–15984 N–15985
wear and cracks. Fig. 6–139 Drive Out Seal Ring Fig. 6–140 Installing Bearing Bushing
2. Inspect bearing bores and

crankcase. Check bore of
bearing of bearing liner of gear
wheel side.
Check bore of bearing bushing
at minimum of two points in
horizontal and vertical position
(Fig. 6–141).
3. Push out bearing bushing that

is to be replaced and install a
new one, using special tool
Deutz number 1–410–06
(driver for camshaft bearing N–15986 N–15987
bushing).
Fig. 6–141 Gauging Bore Fig. 6–142 Force Bushing Inward
To remove bearing bushing
without using a guide bushing,
put bushing under a press, with
driver, from outside bushing,
pushing in (Fig. 6–142).
For installation of new bearing
bushing fasten guide bushing
on bar. Put bearing bushing in
position and push in. Check
spacing of lubricating oil holes
in bearing bushing. The short
spacing must face out. When
bushing is pushed into position
it must be even with top surface
and oil holes must be in
alignment with those in bearing PI–02049 N–15988
bore (Fig. 6–143). Fig. 6–143 Insert Bearing Bushing Fig. 6–144 Insert Closure
600, 600D, 610, 611 Loader
4. Check that closure for camshaft
bore is assembled and that its seat
is tight. When new closure is to be
installed, the old one must be
driven out. Use a sealing material.
Install and force it in with tool
Deutz number 131.018 (Fig.
6–144).
6–5.6 Checking The Oil Pump

End play of pump gear is a measure of
wear of gear type lubricating oil pump.
Do not disassemble pump.
N–15989 PI–02042
1. Put lubricating oil pump in a vise Fig. 6–145 Checking End Play Fig. 6–146 Cutting Starter Ring
with driving gear up. The vise
should have protective jaws and
be lightly tightened on pump.
2. Install a dial indicator with a

magnetic base and check end play
of driving spindle (Fig. 6–145).
6–5.7 Installing A New Gear Starter

Ring On Flywheel
1. Check gear starter ring.

2. To remove starter ring, cut it with a
hand chisel (Fig. 6–146).
N–15990 N–15991
3. Heat new starter ring to about Fig. 6–147 Inspect Front Cover Fig. 6–148 Dismantling Engine Governor
200°C, then install.
6–5.8 Checking Front cover And

Repair Of Engine Governor
1. Remove all loose parts from front

cover.
2. Inspect front cover and parts of

engine governor (Fig. 6–147).
3. To disassemble engine governor,

use driver to force out heavy duty
fastening sleeve and pull speed
control lever from control spindle. N–15992 N–15993
Loosen leaf spring from spindle Fig. 6–149 Remove Snap Ring Fig. 6–150 Insert the Bushing
and remove snap rings on side of
control lever. Pull control spindle from front cover and remove control lever,
seal spring and leaf spring (Fig. 6–148).
4. Remove snap ring from bearing pin for fuel lock. Pull stop lever and torsion
spring (Fig. 6–149).
5. Remove grommets from fuel pressure pins and pull pressure pins. Check
pressure pin and bushing and replace when bad. When bushing is pressed
in position it must project between 0,5 and 1 mm (.0196 inches to .0393
inches) beyond flange face on front cover. Install bushing so 15° internal
level is at extended end (Fig. 6–150). Use tool for valve guide, Deutz number
1–812–13.
6. Pry out sealing ring for governor bearing and replace it with a new one (Fig.
6–151).
PI–02045
Fig. 6–151 Pry Out Sealing Ring
600, 600D, 610, 611 Loader

7. Check needle bearing and
replace it with a new one when
bad. The needle bearing must
be forced out and a new one
installed using a tool for piston
pin bushing, Deutz number
1–310–13 (Fig. 6–152).
8. Install new sealing ring with lip

facing in and press it all around
until it is evenly in position.
PI–02046 N–15994
Fig. 6–152 Install Needle Bearing Fig. 6–153 Check the Closure
9. Check that closure of bore is in

alignment with camshaft
bearing seats and is oil tight.
Replace it with a new one when
bad (Fig. 6–153).
10. Put new gaskets under all plugs

(Fig. 6–154).

11. Remove threaded bushings
from the adjustment screw pin
for stop lever (blocking system)
PI–02040 N–15995
(Fig. 6–155).
Fig. 6–154 Install New Gaskets Under Plugs. Fig. 6–155 Remove Threaded Bushing
12. Remove lock nuts. Turn

threaded pin in and remove
(Fig. 6–156).
13. Install governor in control

position. Turn in threaded pin.
Assemble lock nut with sealing
ring. When lock nut is tight the
threaded end of pin must be
extended about (.4724 inch) 12
mm (Fig. 6–157).
N–15996 N–15997
Fig. 6–156 Remove Lock Nuts Fig. 6–157 Install Governor
14. Install threaded bushing. Make

nut seat against lock nut by
fitting rings between two faces
of nuts (Fig. 6–158).
15. Check full load stop screw for

speed control lever. Install stop
screw complete with a (.12
inch) 3 mm steel washer (Fig.
6–159).
N–15998 N–15999
Fig. 6–158 Install Screwed Bushing Fig. 6–159 Install Stop Screw
600, 600D, 610, 611 Loader
16. Check no load adjustment
screw set in position. Tighten
adjustment screw with a lock
nut so that distance of top of lug
to top face of screw is about
(1.18 inch) 30 mm (Fig. 6–160).
17. Put grease in middle groove of

priming pressure pin and
assemble pin. Install a new
rubber sealing ring in lower
groove (Fig. 6–161).
18. Install torsion spring with long N–16000 PI–02071

offset end down, so that it is in
location over bearing pin. Put Fig. 6–160 Check No–Load Adjusting Screw Fig. 6–161 Installing Rubber Sealing Ring
fuel lock with release lug down
(Fig. 6–162).
19. Turn fuel lock through 270°

counterclockwise (For initial
testing of spring) and push it
down so that release lever
locates under pin. Install snap
ring (Fig. 6–163).

20. Install speed control spindle
with flat end from control lever
side and install thrust washer
(Fig. 6–164).
PI–02072 N–16001
a. Slide spindle fully through Fig. 6–162 Install Torsion Spring Fig. 6–163 Install Snap Ring
and install snap ring in
groove near speed control
lever.
b. Slide speed control lever on
spindle and put in heavy
duty fastening sleeve.
c. Measure end clearance.
Disassemble fitting snap ring
and speed control lever. Push
back spindle and when needed
install a shim.
PI–02003 PI–01999
Fig. 6–164 Install Speed Control Spindle Fig. 6–165 Mount Control Lever
21. Install control lever and push
speed control spindle in further
(Fig. 6–165).
22. Install control lever seal spring

so that short end locates
between two cast dots on cover
and long end is positioned
behind arm on control lever
(Fig. 6–166).
23. Install control leaf spring. Move

speed control spindle farther in
and fasten control fork (Fig.
6–167).
PI–02000 PI–02001
Fig. 6–166 Installing Seal Spring Fig. 6–167 Installing Control Leak Spring
600, 600D, 610, 611 Loader

24. Install snap rings on either side
of control lever on speed control
spindle (Fig. 6–168).
25. Check speed control lever.

Check for free movement of full
load adjustment screw and that
leaf spring for no load and stop
position is in correct order. Put
in basic position. When lock nut
is tightened the thread of
adjustment screw must have
PI–02002 N–16002
extension of about (.354 inch) 9
mm (Fig. 6–169). Fig. 6–168 Inserting Snap Ring Fig. 6–169 Checking Speed Control Lever
26. Slide rubber sealing rings into

groove in bearing bore (Fig.
6–170).
27. Check that a plug is fitted on

opposite sides (Fig. 6–171).
Install one when necessary.
Check engine governor to

make sure that it functions
smoothly.
6–5.9 Check and repair Of the PI–02032 N–16003

Governor
Fig. 6–170 Installing Rubber Sealing Fig. 6–171 Check for Plug
1. Inspect governor dish. Check Rings
thrust and needle bearings and
disassemble when needed. To
disassemble thrust bearing
force out snap ring and remove
loose bearing parts.
2. Assemble thrust bearing for

installation. Hold twenty–one
balls in position with grease
(Fig. 6–172).
3. Install assembled thrust

bearings together with shims
which were removed. The bent PI–02008 PI–02009
tabs must be toward the
bearings and center shims (Fig. Fig. 6–172 Assemble Thrust Bearing Fig. 6–173 Install Thrust Bearing
6–173).
NOTE: When installing governor

check final thickness of
shims and correct when
needed.
4. Install snap ring and check end

clearance of thrust bearing
(Fig. 6–174).
5. Check needle bearing and

when needed, install new. Push
out old bearing and install new
one so that its location is even
with end face (Fig. 6–175). PI–02010 N–16004
Fig. 6–174 Insert Snap Ring Fig. 6–175 Check Needle Bearing
600, 600D, 610, 611 Loader
6. Remove bolt fastening ball
bearing to end of governor
spindle and remove retaining
7. Remove ball bearing from

governor spindle (Fig. 6–177).
8. Check ball bearing. When not in

new condition, install a new
one.
NOTE: When assembling ball

bearing, do not fasten it to N–16005 N–16006
governor spindle. Position Fig. 6–176 Remove Retaining Washer Fig. 6–177 Remove Ball Bearing
it in crankcase.
9. Inspect flyweight holing ring for

wear. When flyweight grooves
have damage, install older rings
with a new one (Fig. 6–178).
10. Inspect flyweights. Check that

they are fastened. A bad
flyweight must have
replacement with new (Fig.
6–179).

6–5.10 Checking And
Replacement Of Connecting Rod
Bearings
N–16007 N–16008
The big end bearings are of Fig. 6–178 Replacing Holder Ring Fig. 6–179 Inspect Flyweights
non–adjustable thin type. Do not
machine or recondition them. The
two bearing halves are supplied in
sizes to match crankshaft undersizes
of .020, 040 (5.08, 10.16 mm).
1. Remove bearings. Refer to

Specifications for wall
thickness (Fig. 6–180).
2. To remove piston from

connecting rod, remove both
snap rings and press out piston
pins (Fig. 6–181).
N–16010
3. Check bearing bore. Fig. 6–180 Bearing Wall Thickness Fig. 6–181 Press out Piston Pin
Assemble cap to connecting rod.

Check that they have same
identification number (Fig. 6–182).
Bolt cap to connecting rod. Tighten to
30° + 60° and lock down bolts (Fig.
6–183). Use micrometer and set
internal dial indicator to (2.2444 inch)
57 mm.
N–16011 N–16012
Fig. 6–182 Assembling Cap to Rod Fig. 6–183 Lock Down the Bolts
600, 600D, 610, 611 Loader

Check the bore at various diagonal
NOTE: When new bearings are

needed, follow above steps
to check bearing clearances.
6–5.11 Checking And Replacement

Of Piston Pin Bushing
1. Check bore of piston pin bushing.
Check bore of piston pin bushing
at several diagonal positions (Fig. N–16013 N–16014
6–185).
Fig. 6–184 Gauge the Bore Fig. 6–185 Gauge the Piston Pin Bore
NOTE: When reading is above
specified tolerance by more
than (.0078 inch) 0,22 mm,
piston pin bushing must
have replacement by a new
one.
2. To remove a piston pin bushing,

push it out with tool, Deutz number
1–310–13. When installing a new
bushing, make sure that it is

located in center of little end of
connecting rod. The oil holes must
be in correct position (Fig. 6–186).
NOTE: When installing a N–16015 N–16016
connecting rod, first check it
in a checking alignment Fig. 6–186 Pressing in Piston Pin Bushing Fig. 6–187 Checking Bore Alignment
fixture to determine if bores
are square and in alignment.
The bearings must be
included. Measure at a
distance of (3.937 inches)
100 mm from rod face, pin 1
installed in small end must
not be more than (.003 inch) 2
0,008 mm out of alignment
(Fig. 6–187). 3
6–5.12 Checking Cylinders 4
NOTE: A standard size cylinder can
be cut to larger sizes .020 or b
.040 inch (5,08, 10,16 mm) PI–02016 a
only.
Fig. 6–188 Measure Working Surface Fig. 6–189 Gauging Points
1. Using a micrometer with internal dial gauge set to size of bore (Fig. 6–188).
2. Measure working surface of cylinder bore (Fig. 6–189).
3. Check top and bottom contact surfaces of cylinder to make sure they are flat.
6–5.13 Checking And Measuring Pistons
NOTE: Pistons are available in three diameters to match the corresponding

undersize of the cylinders.
1. Use a plier to measure the diameter of piston. Size is stamped on crown of

piston (Fig. 6–190).
N–16018
Fig. 6–190 Piston Diameter Marking
600, 600D, 610, 611 Loader
2. Remove piston rings with an
expander tool (Fig. 6–191).
1
3. Clean piston and inspect for 2
visual damage and wear.
Check the piston bosses and 3
ring groove (Fig. 6–192).
4
4. Measure vertical clearance of
rings and grooves (Fig. 6–193).
5. Install piston rings individually

in respective cylinders and use
a piston to press them down to N–16019
a depth of about (1.2 inch) 30
mm. Measure the gap Clarence Fig. 6–191 Removing Piston Rings Fig. 6–192 Inspect the Piston
(Fig. 6–194).
6. Inspect piston pins for wear

(Fig. 6–195).
NOTE: When piston pin bosses

or piston pins are not up to
standard complete piston
must have replacement
made. Piston pins must
always be installed in

same original pistons.
Use an expander tool for installing N–16021 PI–02048

piston rings. The identification marks
on rings must face upward. In case of Fig. 6–193 Ring Vertical Clearance Fig. 6–194 Measuring Ring End Clearance
conformable oil rings, the spiral
springs must first be individually fitted
(Fig. 6–196).
NOTE: Install piston rings in

following order: (Fig.
6–197).
Grooved 4. Single land
beveled conformable oil
control ring.
Grooved 3. Stepped
compression ring
N–16022 N–16023
Grooved 2. Stepped Fig. 6–195 Inspect Piston Pins Fig. 6–196 Install Rings
compression ring.
Grooved 1. Top
compression ring
(Chromium plated).
6–5.14 Repair Of Cylinder Head
1. Fasten cylinder head in swivel

stand (Fig. 6–198).
N–16024 N–16025
Fig. 6–197 Ring Positions Fig. 6–198 Mount Cylinder Head in Stand
600, 600D, 610, 611 Loader

2. Remove tightening screw of
rocker fastener (Fig. 6–199).
3. To remove rocker, pull bearing

bushing from one side (Fig.
6–200).
4. Remove loose push rods

protective tubes from cylinder
head top.
PI–02011 PI–02012
Fig. 6–199 Remove Rocker Mounting Screw Fig. 6–200 Withdraw Bearing Bushings
5. Remove valves and valve
springs (use valve compressor,
Deutz number 1–310–01) (Fig.
6–201).
6. Remove top of cylinder head.
7. Inspect cylinder head for cracks

and external damage.
8. Check cylinder head contacting

surface. It must be flat and
square. It can be faced new if
the distance from the face to
bottom of cylinder head is within
tolerance (Fig. 6–202). PI–02013 N–16026
Fig. 6–201 Removing Valves Fig. 6–202 Checking Cylinder Head
9. Small damage to cylinder head

contacting surfaces can be
removed by grinding with fine
paste put on cylinder barrel.
When surface has more
damage, it must be faced new
with cutter tool, Deutz number
1–410–03 (Fig. 6–203).
10. Recondition valve seating rings

that are not to be installed new.
Use valve seating tool, Deutz
number 1–310–08 (Fig.
6–204). PI–01982 N–16027
Fig. 6–203 Refacing Cylinder Head Surface Fig. 6–204 Using Valve Re–seater
11. Install new valves. Measure

distance from valve head to
bottom of cylinder head (Fig.
6–205).
12. To install a valve seating ring

proceed as follows:
a. Drill to bottom of valve
seating ring, without
damaging light metal collar
(Fig. 6–206).
PI–01984 PI–02030
Fig. 6–205 Measuring Valve Head Clearance Fig. 6–206 Drill to Bottom of Ring
600, 600D, 610, 611 Loader
b. Use a hard chisel at an
angle of 90° to the drilled
seating ring. Hit chisel and
pry out loosened ring (Fig.
6–207).
c. Heat cylinder head in a
heating cabinet or furnace
to a temperature of about
250°C. Put new valve
seating ring, beveled side
first, on driver tool and force
ring in until hits bottom (Fig.
6–208).
PI–02031 N–16028
NOTE: The valve seating ring Fig. 6–207 Removing Old Ring Fig. 6–208 Driving in New Ring
must be square in seat on
bottom.
13. The valve stem clearance must

be measured just above valve
guide. Install a valve and move
it sideways in guide (Fig.
6–209).

14. When it is necessary to make
replacement of a valve guide,
proceed as follows:
PI–02058 PI–02004
a. Heat cylinder head in a
heating cabinet or furnace Fig. 6–209 Valve Stem Clearance Fig. 6–210 Drive Out the valve Guide
to about 150°C. Use tool,
Deutz number 1–812–03,
to force out valve guide
from the seating ring side
(Fig. 6–210).
b. Remove snap rings from
old valve guide and install it
on new guide.
c. With cylinder head heated
to 250°C., use driver to
force longer end of valve
guide from rocker arm
support side until it is in seat
on fastening wire (Fig. PI–02005 PI–02006
6–211).
Fig. 6–211 Driving in Valve Guide Fig. 6–212 Ream Valve Guide Bore
d. Use reaming tool to bore
valve guide after cylinder
head has become cold
(Fig. 6–212).
15. Install steel washers for

cylinder head studs (Fig.
6–213).
16. Install top element of cylinder

head and fasten it with four
studs (Fig. 6–214).
PI–02007 PI–02017
Fig. 6–213 Insert Steel Washers Fig. 6–214 Mount Cylinder Head
600, 600D, 610, 611 Loader

17. Install a new rubber O–ring in
valve spring retainer to the
valve guide (Fig. 6–215).
18. Measure length of valve springs

for tolerance (Fig. 6–216).
19. To install valve, assemble

individual valve springs with
spring retainer, compress the
valve spring and install the
collets (Fig. 6–217).
PI–02018 PI–02019
Fig. 6–215 Install New Rubber O–ring Fig. 6–216 Measure Length of Valve Springs
6–5.15 Repair Of Rocker Arms
1. Check rocker arms and make

replacement of worn parts.
NOTE: When installing bearing

bushing make sure oil
holes are in correct
position. The second hole

in bushing must face up in
rocker arm (Fig. 6–218).
PI–02020 PI–01997
6–5.16 Repair Of Cooling Air Fig. 6–217 Installing Valves Fig. 6–218 Replacing Rocker Arm Bushing
Blower
1. Remove fastening bolt and

remove fan.
2. Use soft metal bar to force out

bearing spindle (Fig. 6–219).
3. Remove grooved ball bearing

from spindle (Fig. 6–220).
4. Remove snap ring in front of

second groove ball bearing. PI–02061 N–16030
Use driver to force groove ball Fig. 6–219 Drive Out Bearing Spindle Fig. 6–220 Remove Grooved Ball Bearing
bearing out of blower casing.
5. Make replacement of both

groove ball bearings with new
ones and fill them with high
melting point grease.
6. Press in small groove ball

bearing with closed side facing
down (Fig. 6–221).
7. Put snap ring in groove in front

of installed groove ball bearing
(Fig. 6–222). PI–02035 PI–02036
Fig. 6–221 Press in the Ball Bearing Fig. 6–222 Install Snap Ring
600, 600D, 610, 611 Loader
8. Push large groove ball bearing
on spindle with closed side
facing belt pulley (Fig. 6–223).
9. Push spindle with bearing into

seat location in housing (Fig.
6–224).
10. Inspect fan to make sure it does

not have damage.
N–16031 N–16032
11. Install the fan (Fig. 6–225).
Fig. 6–223 Install Large Ball Bearing Fig. 6–224 Press in Spindle
12. Fasten blower in position. Put

blower and belt pulley in a vise.
Tighten bolt (Fig. 6–226).

6–5.17 Removing And Installing A
Fuel Injection Nozzle
PI–02073 PI–02029
1. Turn out the union nut on nozzle Fig. 6–225 Mount Impeller Fig. 6–226 Secure Blower
holder. Remove the parts in
nozzle holder (Fig. 6–227).
2. Remove high pressure pipe

union. Remove orifice plate.
3. Thoroughly clean all parts with

clean diesel fuel. With an air jet
blow out high pressure filter and
feed pipe union from the thick
end (Fig. 6–228).
4. Inspect components.
N–16033 N–16034
The nozzle needle is a near Fig. 6–227 Disassemble Nozzle Holders Fig. 6–228 Clean all Parts
tight fit in nozzle body and parts
must not be mixed. Do not
touch the finished surfaces.
New nozzles must be washed
in diesel fuel to remove rust and
old grease. A good needle must
slide down slowly and smoothly
into its seat when put into
vertical held nozzle (Fig.
6–229). Put inspection clean
components on a piece of clean
rag until ready to be installed.
5. Put orifice plate in nozzle holder

and connect high pressure pipe
union (Fig. 6–230). N–16035 N–16036
Fig. 6–229 Free Movement of Needle Fig. 6–230 Insert Orifice Plate
600, 600D, 610, 611 Loader

6. Install shims (Fig. 6–231).
7. Install compression ring and thrust pin (Fig. 6–232).
8. Assemble fastening nut to nozzle holder (Fig. 6–233).
9. Install bushing and nozzle making sure that they are in center location (Fig.
6–234).
10. First tighten union nuts finger tight, then tighten to (40–50 ft.–lbs.) 5.57
M/kgF.
11. Check nozzle and make adjustment.

N–16037
Fig. 6–231 Reinsert Shims
6–6 GENERAL ENGINE DATA (F2L410)
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cylinder Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vertical (in line)
Cylinder Bore (F2L410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54 (90)
Cylinder Bore (F2L411) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.622 (92)
Piston Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.94 (100)
Total Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1272 cm3 (77.6 cu. in.)
Working Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 stroke diesel
Direction of Rotation . . . . . . . . . . . . . . . . . . . . . Counterclockwise (Flywheel end)
Maximum Permissible Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2700 RPM
Lowest Speed Under Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 RPM
Lowest Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 ±50 RPM

Governed Flywheel Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . 24 @ 2700 RPM
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
Inlet Valve Opening Angle Before TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34°
Inlet Valve Closing angle After BDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.5° N–16038
Exhaust Valve Opening Angle Before BDC . . . . . . . . . . . . . . . . . . . . . . . . . . 79.5°
Exhaust Valve Closing Angle After TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° Fig. 6–232 Install compression Spring
Weight of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 kg (322 lb.)
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure
Air Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axial–flow Blower
Overall Dimensions of Engine
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541 (21.3)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510 (20.08)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 676 (26.6)
6–7 Torque Specifications (Deutz Engine)
ITEM PRELOADING TIGHTENING TOTAL
Cylinder Head Bolts 21.5 ft.–lbs. (29 Nm) 30° 60° 60° 150°
Injector Hold–Down 21.5 ft.–lbs. (29 Nm) 60° 60° 120°
Connecting Rod 21.5 ft.–lbs. (29 Nm) 30° 60° 90° N–16039
Camshaft Bearing Flange 25 ft.–lbs. (34 Nm) Fig. 6–233 Install Securing Nut
Bearing Support 21.5 ft.–lbs. (29 Nm) 30° 30° 60°

Blower Mounting Bolts 25 ft.–lbs. (34 Nm)
V–Belt Pulley 21.5 ft.–lbs. (29 Nm) 90° 90°
Intake Manifold 11 ft.–lbs. (15 Nm)
Crankshaft Gear 21.5 ft.–lbs. (29 Nm) 30° 30° 60°
Oil Suction Pipe 36 ft.–lbs. (49 Nm)
Flywheel 21.5 ft.–lbs. (29 Nm) 60° 30° 90°
Rocker Arm Bolts 21.5 ft.–lbs. (29 Nm) 45° 45°
Balance Weight 21.5 ft.–lbs. (29 Nm) 30° 30° 60°
N–16040
Alternator Pulley Nuts 40–60 (54–81)
Fig. 6–234 Install Spacer and Nozzle
600, 600D, 610, 611 Loader
6–8 FITS, CLEARANCES, ADJUSTMENTS – DEUTZ ENGINE
6–8.1 Oil System
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 28.5 PSI (196,6 kPa) @ 1500 RPM
Capacity of system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 quarts (4 L)
End Clearance in Oil Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .004 (,1 mm)
6–8.2 Fuel System
Pressure of Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . 4–5 PSI (27,5–34,5 kPa)
Make of Fuel Injections Pump . . . . . . . . . . . . . . . . . . . . . . Bosch PF 2K70A414/2
Make of Fuel Injection Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . DLLA 152 S 533
Release Pressure of Injection Nozzle . . . . . . . . . . . . . . . . New–2560–2675 PSI
(17,650–18,450 kPa)
Old–2490–2600 PSI (17,170–17,925 kPa)
Injections timing (Start of Injection) . . . . . . . . . . . . . . . . . . . . . . . . . . 25° B.T.D.C.
Distance from Injection Pump Mounting Flange to Camshaft
(Including gasket and shims) . . . . . . . . . . . . . . . . . 3.248–3.256 (82,5–82,7 mm)
6–8.3 Governor, Front Cover and Throttle
Distance from governor Bearing Cup to Engine Block . . 3.37–3.38 (85,6–85,7)
End Play in Throttle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . .008–.043 (,2–1,1 mm)
Engine High Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2575 RPM
Engine Low Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 RPM
6–8.4 Cylinder Head and Valves

I.D. of Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315–3155 (8.8,015 mm)
I.D. of Bore for Exhaust Valve Seat . . . . . . . . . . . . . 1.5354–1.5364 (39–39,025)
I.D. of Bore for Intake Valve Seat . . . . . . . . . . . . . . . . 1.378–1.379 (35,–39,025)
Valve Seat Width, Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .040–.055 (1,–1,4)
Valve Seat Width, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .031–.033 (8,–,83)
Valve Seat Angle, Exhaust and Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44–1/2°
Valve Stem Diameter, Intake . . . . . . . . . . . . . . . . . . . . . .3134–.314 (7,96–7,975)
Valve Stem Diameter, Exhaust . . . . . . . . . . . . . . . . . . . . .3118–.3126 (7,92–7,94)
Maximum Distance Valves may be Recessed into Head . . . . . . . . .020 (,5 mm)
Maximum Distance Valves may Protrude from Head, Intake . . . . . . . .083 (2,11)
Maximum Distance Valves may Protrude from Head, Exhaust . . . . . .095 (2,42)
Valve Clearance, Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 (,15 mm)
Maximum Length of Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.114 (231,5)
6–8.5 Cylinder and Piston
Cylinder Bore (standard) . . . . . . . . . . . . . . . . . . . . . . . . 3.622–3.623 (92–92,022)
Maximum Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .012 (,3 mm)
Piston Diameter (standard) . . . . . . . . . . . . . . . . . 3.6197–3.620 (91,940–91,949)
Piston Diameter (1st oversize) . . . . . . . . . . . . . 3.6394–3.6397 (92,440–92,449)
Piston Diameter (2nd oversize) . . . . . . . . . . . . . . 3.659–3.6594 (92,940–92,949)
Wrist Pin Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1812–1.1814 (30,002–30,007)
Wrist Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . 1.1809–1.1811 (29,996–30,000)
Piston Ring Side Clearance, Compression Rings . . . . . . . . . . . . . . . . . . .012 (,3)
Piston Ring Side Clearance, Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 (,15)
Ring End Gap, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .014–.022 (,35–,55 mm)
Ring End Gap, 2nd & 3rd Rings . . . . . . . . . . . . . . . . . . . .018–.026 (,45–,65 mm)
Maximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .079 (2, mm)
Distance Between Piston & Head . . . . . . . . . . . . . . . . . . . . . . .031–.039 (,80–1,0)
Compression Pressure . . . . . . . . . . . . . . . . . . . . . 355–575 PSI (2445–3960 kPa)
NOTE: Both cylinders must be within 35 PSI (240 kPa).
I.D. of Hole for Wrist Pin Bushing . . . . . . . . . . . . . . 1.3386–1.3392 (34,–34,016)

I.D. of Wrist Pin Bushing . . . . . . . . . . . . . . . . . . 1.1877–1.1841 (30,040–30,076)
I.D. of Big End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2441–2.2448 (57–57,019)
Rod–to–Crankshaft Clearance . . . . . . . . . . . . . . . . . . . . . .002–.0044 (,050–,112)
Rod–to–Crankshaft (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .012 (,3)
Rod–to–Crankshaft Side Clearance . . . . . . . . . . . . . . . . . . .006–.012 (,170–,271)
600, 600D, 610, 611 Loader

6–8.6 Camshaft, Crankshaft, Bearings
Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006–.024 (,15–,60)
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .039
I.D. of camshaft Bushing . . . . . . . . . . . . . . . . . . . 1.8901–1.8923 (48,01–48,064)
Diameter of Crankpin, Standard . . . . . . . . . . . . . . 2.046–2.0468 (51,971–51,99)
Diameter of Crankpin, 1st Undersize . . . . . . . . . 2.0264–2.0272 (51,471–51,49)
Diameter of Crankpin, 2nd Undersize . . . . . . . . 2.0067–2.0075 (50,971–50,99)
Diameter of Crankpin, 3rd Undersize . . . . . . . . . 1.9870–1.9878 (50,471–50,49)
Width of Crankpin . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3386–1.3401 (34,–34,039)
Diameter of Crankshaft Main Journals, Standard . . . . . . . . . . . . 2.4398–2.4406
(61,971–61,99)
Diameter of Crankshaft Main Journals, 1st Undersize . . . . . . . . 2.4201–2.4209
(61,471–61,49))
Diameter of Crankshaft Main Journals, 2nd Undersize . . . . . . . . 2.4004–2.4012
(60,971–60,99))
Diameter of Crankshaft Main Journals, 3rd Undersize . . . . . . . . 2.3807–2.3815
(60,471–60,490)
Crankshaft Center Journal, Standard . . . . . . . . . . 2.361–2.3618 (59,971–59,99)
Crankshaft Center Journal, 1st Undersize . . . . 2.3414–2.3421 (59,471–59,490)
Crankshaft Center Journal, 2nd Undersize . . . . 2.3217–2.3224 (58,971–58,99)
Crankshaft Center Journal, 3rd Undersize . . . . . 2.302–2.3028 (58,471–58,49)
Maximum Out–of–Round Tolerance of Journals . . . . . . . . . . . . . . . . . .0027 (,07)
End Play of Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .008–.016 (,2–,4)
Hardness of Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rc 53–60
6–9 SPECIAL TOOLS

6–9.1 Mainframe & Hydraulics Part Number
Wrench, Axle Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Parts Manual
Chain Breaker Tool (Size No. 50)
Chain Breaker Tool (Size No. 80)
Tank Spreaders (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6501120–Clark
Hydraulic Cylinder Spanner Wrench . . . . . . . . . . . . . . . . . . . . . . . . 6506050–Clark
Boom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Parts Manual
Y–90 Tester & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Parts Manual
6–9.2 Deutz Engine Tools
100020 Compression checking tool
100030 Compression check tool
101900 Angle of turn gauge for head bolts
101910 Angle 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
600, 600D, 610, 611 Loader

610,611ServiceManual#6556276–DeutzEngineServiceSection
600, 600D, 610, 611 Loader

PETTER ENGINE SERVICE
Paragraph Page
Number Number
CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.7 7–7
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.3 7–3
CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 7–1.8 7–8
CONNECTING ROD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 7–1.2 7–2
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.2 7–2
CYLINDER AND PISTON INSTALLATION . . . . . . . . . . . . . . . . 7–1.9 7–8
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 7–1.11 7–9
DECOMPRESSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 7–1.14 7–10
ENGINE DISASSEMBLY AND REPAIR . . . . . . . . . . . . . . . . . . 7–1 7–1
FUEL AND OIL FILTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 7–1.17 7–10
FUEL FILTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.16 7–10
FUEL PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.15 7–10
INJECTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.19 7–11
LUBRICATING OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.6 7–6
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.5 7–4
OIL PUMP AND GOVERNOR ASSEMBLY REMOVAL . . . . . 7–1.4 7–4
PISTON ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.10 7–9
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2 7–12
TIMING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1.18 7–10
VALVE ROCKER ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . 7–1.13 7–10

VALVE ROCKER GEAR INSTALLATION . . . . . . . . . . . . . . . . . 7–1.12 7–10
PETTER ENGINE
SERVICE
600, 600D, 610, 611 Loader

600, 600D, 610, 611 Loader

7 PETTER (ENGINE
RECONDITIONING)
7–1 ENGINE DISASSEMBLY AND
REPAIR
1. Remove crankcase oil.
2. Remove exhaust manifold

assembly ( Fig. 7–1).
3. Disconnect pump to injection C–02120

pipes, disconnect air cleaner Fig. 7–1 Remove Exhaust Manifold Fig. 7–2 Remove Rocker Cover
hose, remove manifold and
cylinder air housing.
4. Remove rocker cover nut, pull

decompressor lever away from
rocker cover, against spring
pressure, lift cover off (Fig.
7–2).
5. Remove fuel injectors (Fig.

7–3).
6. Remove rocker assembly and

valve caps. Remove push rods B–02371 C–02122
(Fig. 7–4). Fig. 7–3 Remove Fuel Injectors Fig. 7–4 Remove Rocker Assembly
7. Remove cylinder head nuts and

remove cylinder heads.
Remove push rod covers and
seals (Fig. 7–5).
8. Mark crankcase and cylinder

for assembly position. Turn
crankshaft until piston is TDC
and pull cylinder barrel from
piston (Fig. 7–6).
C–02119 C–02118
Fig. 7–5 Remove Cylinder Head Fig. 7–6 Remove Cylinder Barrel
NOTE: Check number and size of
shims between cylinder
and crankcase, before
removal (Fig. 7–7).
9. Remove piston by removing

piston pin snap rings (Fig. 7–8).
C–02121 B–01878
Fig. 7–7 Cylinder Shims Fig. 7–8 Remove Piston Pin Snap Rings
600, 600D, 610, 611 Loader
10. Remove four retainer bolts and
remove crankshaft extension.
Remove two flywheel retainer
bolts and install two longer bolts
of same diameter. Remove the
remainder retainer bolts and
use puller to remove flywheel
(Fig. 7–9).
11. Remove flywheel air guide

inside bell housing and the fan
guard (Fig. 7–10).
B–02372
Fig. 7–9 Removal of Flywheel
7–1.1 Removal Of Connecting Rod C–02097

Fig. 7–10 Remove Air Guide & Fan Guard
1. Put engine on its flywheel
housing. Remove oil pan
fastening nuts, oil pan and air
guide plate (Fig. 7–11).

2. Loosen large end bolts and
remove connecting rods.
Check position in which B–02310
connecting rod caps are Fig. 7–11 Remove Air Guide Plate
installed, number sides
together for identification (Fig.
7–12).
B–02386
Fig. 7–12 Remove Connecting Rod Caps
7–1.2 Removal Of Crankshaft
1. Remove gear cover nuts, cover

has dowel fit to crankcase.
Remove dowels to prevent
damage (Fig. 7–13).
C–02147
Fig. 7–13 Remove Timing Gear Cover
600, 600D, 610, 611 Loader

2. Remove bolts holding
crankshaft gear wheel. The
gear wheel has dowel fit to
crankshaft. Remove dowels.
Do not damage teeth on gear
wheel (Fig. 7–14).
3. Remove oil strainer assembly.

Remove bolts, locking plates
and bottom half of bearing.
Remove top half of bearing
housing, turn it 180° by turning
C–02102
crankshaft (Fig. 7–15).
Fig. 7–14 Remove Crankshaft Bear
4. Remove nuts, washers and oil

seal housing. Remove thrust
collar retainer bolt and plate. B–02370
Remove thrust collar.
Fig. 7–15 Remove Main Bearing
5. Remove main bearing housing

nuts and washers. Remove
housing and pull crankshaft
(Fig. 7–16).

7–1.3 Removal Of Camshaft
1. Remove fuel injection pumps.

check number of shims and
thickness between fuel pump
flanges and crankcase (Fig.
7–17). these shims control fuel
pump timing. Remove fuel filter
C–02094 B–02342
2. Put rubber band around stems Fig. 7–16 Remove Crankshaft Fig. 7–17 Check Number of Shims
of valve tappets to prevent
damage to toe pieces when
pulling camshaft. Turn
camshaft so fuel pump tappets
are clear of shaft. Remove
camshaft bearing housing nuts
through holes in gear wheel.
Then camshaft and bearing
housing can be pulled (Fig.
7–19).
A–02322
Fig. 7–18 Fuel Filter Assembly Fig. 7–19 Removing Camshaft
600, 600D, 610, 611 Loader
3. Pull fuel pump tappets (Fig.
7–20).
4. To remove camshaft
gearwheel, hold camshaft in a
vice using protected vice
fasteners so that there will be
no damage to the shaft.
Remove gearwheel retainer
plate, bolt, plate and retainer
plate oil seal. Pull gear wheel
(Fig. 7–21). Remove bearing
housing assembly.
C–02105
7–1.4 Removal Of Oil Pump And Fig. 7–21 Remove Camshaft Bearing Housing
Governor Assembly
1. Remove bolts fastening speed
control plate. Push out speed
control lever pin and pull lever. A–02146
Remove lever shaft boss, first Fig. 7–20 Pull Fuel Pump Tappets
pushing out stop/run lever pin,
then remove lever, shaft bolt
and oil seal. Remove
adjustment bolt, spring and
pillar assembly from governor
rack. Do not change
adjustment bolt (Fig. 7–22).

Remove governor lever, speed
spring and shaft assembly.
Remove stop/run lever shaft
assembly. Pull governor rack
without doing damage to shaft B–02311
(Fig. 7–23). Fig. 7–22 Remove Governor Level
2. Remove oil pump retainer bolts,

pump and governor assembly.
Remove snap ring retainer for
governor thrust cone,
thrustwasher, cone and
governor balls (Fig. 7–24).
7–1.5 Oil Filter C–02103

1. Remove bolt at center of filter Fig. 7–23 Governor Rack Removal
cover and pull cover and
element. Remove relief valve,
plunger and spring (Fig. 7–25).
NOTE: Clean all parts and inspect C–02092

for wear. All worn parts Fig. 7–24 Removing Oil Pump
must be installed new. The
bearings are of precision
thin wall steel backed
sleeve type, lined with
bearing metal. The
bearings can be pressed
or driven out.
Check that crankcase oil holes
are clean, make sure that part
numbers on outer face of
bearings are not rough. Burrs
must be removed before
bearing is put into its housing.
2. Remove main bearing, gear
end, using correct tool (Fig. B–02308 C–02106
7–26).
Fig. 7–25 Remove Oil Filter Fig. 7–26 Remove Main Bearing (Gear End)
600, 600D, 610, 611 Loader

3. When installing a new main
bearing, gear end, use correct
tool. New bearings are of
special size to give correct fit
when in position.
NOTE: Undersize bearings are

available in size .020 inch
or .040 inch (5,08, 10,16
mm).
B–01252
4. Inspect camshaft bearings, Fig. 7–27 Camshaft, Gear, and Flywheel End Bearing
gear and flywheel end. These
are pressure lubricated bearing
bushings and are installed
using correct tool (Fig. 7–27).
5. Remove flywheel end main

bearing after removing
thrustwashers. Use correct tool
for removal (Fig. 7–28).

6. Install a new main bearing,
flywheel end (Fig. 7–29).
A–02327
Fig. 7–28 Remove Flywheel End Main Bearing
7. Install new crankshaft
thrustwashers, check that
groove sides are away from
bearing housing. The washers
are dowel positioned and must
be installed with new dowel pins
(Fig. 7–30).
A–02328
8. Inspect crankshaft bearing Fig. 7–29 Install New Bearing (Flywheel End)
journals and crankpins.
B–01251
Fig. 7–30 Install Crankshaft Thrust Washers
600, 600D, 610, 611 Loader

9. Before installing crankshaft,
check that journal bearing
surfaces and oil holes are clean
(Fig. 7–31).
10. Add lubricant to gear end main

bearing and shaft journals then
install crankshaft. Install top
half of intermediate main
bearing housing after first
putting lubricant on bearing and
center journal of shaft (Fig.
7–32).
A–02144 B–02340
Fig. 7–31 Oil Outlet on Crankshaft Fig. 7–32 Install Crankshaft
11. Lubricate baring and journal,
then install flywheel end main
bearing housing using a new
12. Install new O–ring then install

shaft thrust collar (Fig. 7–34).

13. Install thrust collar and fasten
this with collar key. Inspect oil
seal and housing before
installation (Fig. 7–35).
C–02099 C–02101
Fig. 7–33 Install Main Bearing Housing Fig. 7–34 Install Shaft Thrust Collar
14. When housing and seal is new,

check that seal is installed to
correct rotation, which is
marked by an arrow stamped
on seal (Fig. 7–35).
15. Check that oil seal and housing

are in position (Fig. 7–36).
16. Install fan guard and air guide in

correct positions (Fig. 7–37). A–02318 C–02100
Fig. 7–35 Inspect Oil Seal & Housing Fig. 7–36 Oil Seal & Housing Position
7–1.6 Lubricating Oil Pump
1. Check condition of rotor and

stator. When worn, install new
pump. Put engine oil into pump
through opening before
installing on engine. Install new
gasket, install pump and tighten
bolts to 10 ft.–lbs. (1.39 Kgfm)
(Fig. 7–38).
C–02098 B–01256
Fig. 7–37 Fan & Air Guide Fig. 7–38 Oil Pump
600, 600D, 610, 611 Loader

2. Install valve tappets and hold in
position using rubber bands.
Install fuel pump tappets and
socket headed plugs. 3/4 inch
BSP (taper) (Fig. 7–39).
C–02107
Fig. 7–39 Install Fuel Pump Tappets
7–1.7 Installation Of Camshaft

(Fig. 7–40)
2 3
1. Inspect fuel pump tappet 2
bushing for wear, install new
when needed. Check 6
thrustwashers (1) for wear and
install new if worn. When
washers are removed, install
new dowel pins (2). Put

lubricant on bearing bushing 4
and shaft journal surface.
Install bearing housing 5
assembly (3) onto shaft. Check 1
B–01252
that keyway is in line with key
(4). Install new oil seal ring (5) Fig. 7–40 Camshaft
behind gear holding plate (6),
then install plate and fastening
bolt.
2. Lubricate gear end bearing

bushing, and camshaft bearing
surfaces, put in camshaft
assembly. Install and tighten
camshaft bearing housing nuts
and washers. Tighten gear
fastening bolt to 25 ft.–lbs.
(3,46 Kgfm) (Fig. 7–41).
3. Lubricate and install bottom half B–02369

of intermediate main bearing
housing assembly. Tighten Fig. 7–41 Torquing Gear Fastening Bolt
fastening bolts in correct
sequence. All bolts to be
tightened finger tight, then
tighten evenly working
diagonally across bearing cap
until bolts are tightened to 25
ft.–lbs. (3,46 Kgfm).
4. Install crankshaft gear

checking that teeth marked with
dots are in position. Tighten
bolts to 35 ft.–lbs. (4,84 Kgfm)
(Fig. 7–42). CAMSHAFT BALANCE
CAMSHAFT–CRANKSHAFT
TIMING TIMING
Fig. 7–42 Timing Crankshaft Gear
600, 600D, 610, 611 Loader
5. Install governor assembly,
using new gasket and oil seal
rings (Fig. 7–43).
6. Check governor thrust

clearance. Move stop/run lever
into Run position, then check
clearance between thrust
bearing and fork on governor
lever. Correct clearance is
between 0.005–0.025 inch
(0,27–0,635 mm), with fuel
pump rack in full fuel position.
Install gear cover using new
B–01253
cover gasket.
Fig. 7–43 Governor Assembly
7. Install flywheel (Fig. 7–44).
8. Tighten bolts to 35 ft.–lbs. (4,84

Kgfm).
9. Check crankshaft end play.

This should be 0.0075–0.0185
inch (0,191–1,470 mm) (Fig.
7–45).
7–1.8 Connecting Rod Assembly

1. When needed, install a new
small end bushing in pistons.
Check that oil feed hole in
bushing is in alignment with
connecting rod hole. Before C–02093
installing connecting rods, Fig. 7–44 Install Flywheel
assemble cap and rod with new
bearings, checking that bearing
halves are in correct position.
When assembling connecting
rods to crankshaft, check that
matching numbers are together
on correct side and that
connecting rod cap is towards
dipstick side of engine (Fig.
7–46). Tighten bolts to 40
ft.–lbs. 5,53 Kgfm) torque.
2. Install oil pump using a new
gasket and air guide, with
opening toward gear end of
engine (Fig. 7–47).
B–02367
7–1.9 Installation Of Cylinders Fig. 7–45 Crankshaft End Play Fig. 7–46 Install Connecting Rod Caps
And Pistons
1. Check the cylinders for wear.

Always hone the bores using
medium grade emery cloth.
Clean cylinders after they are
honed. To check piston rings for
wear, put piston in cylinder
towards end of bore and about
1/2 inch (12,7 mm) from bottom
crown to check that it is level in
bore. The gap can now be
checked with a feeler gauge
and maximum permissable
wear can not be more than
0.040 inches (1,02 mm). New
ring gap is 0.010–0.015 inches
(0,25–0,38 mm) A–02145
Fig. 7–47 Air Guide
600, 600D, 610, 611 Loader

7–1.10 Piston Assembly (Fig.
7–48)
1. Assemble rings on piston in

correct order, with correct face
up. The scraper rings must be
put in fourth (bottom) groove,
the two stepped compression
rings in third groove and second
groove, wtih step facing up,
chrome compression ring in the
top groove with widest internal
chamber facing up. Check that
ring gaps are not in line but
spaced around piston. Install B–02309
piston on connecting rods and
install piston pin. Check that Fig. 7–49 Install cylinders
snap ring is correctly installed in
its groove. Rings must not have
play or be solid in groove. To
check; with piston held in a
horizontal position, rings must
not fall down, unless piston is Fig. 7–48 Piston Assembly
moved. Before installing the
cylinders, check that length of
studs from face of crankcase to
top of studs are correct (i.e.
8.370–8.410 inches). The
studs can appear loose in their

helicoil fittings, but this is
correct (Fig. 7–48).
2. Install shims between cylinder
and crankcase. Thickness of
shims control head clearance
between piston and cylinder
head at T.D.C. Lubricate
cylinder bores, piston,
compressing rings by hand
(Fig. 7–49).
3. The head clearance must now
be checked. Put three pieces of
lead wire approximately 1/2
inch long, on top of piston
crown. Install cylinder head and
tighten bolts. Turn crankshaft
over top dead center. A–02319
4. Remove cylinder head and Fig. 7–50 Lead Wire thickness

measure thickness of lead wire
with a micrometer. Correct
thickness of wire when flat is
0.032–0.037 inch (0,81–0,94
mm). When clearance is not
correct, remove or add required
shims to give correct head
clearance (Fig. 7–50).
5. Install push rod covers using
new gaskets and new seals.
7–1.11 Installation Of Cylinder

Heads
1. Tighten cylinder head nuts
correctly and in right sequence.
Tighten each nut until finger
tight. Then tighten each nut 1/4
of a turn at a time, diagonally
across cylinder head. Tighten
to 34 ft.–lbs. (4,70 Kgfm).
Check with a straight edge
before tightening cylinder head B–02383
nuts (Fig. 7–51). Fig. 7–51 Install Cylinder Head
600, 600D, 610, 611 Loader

7–1.12 Installation Of Valve Rocker Gear
1. Install valve push rods and rocker assemblies. Rocker nut must be tightened
to 15 ft.–lbs. (2,07 Kgfm).
7–1.13 Adjustment Of Valve Rockers
1. Loosen decompressor adjustment lock nuts and screw out adjustors clear
of decompressor cam. Make adjustment of valve rocker clearance. Set
engine with both valves closed and piston at T.D.C. firing stoke. Loosen
rocker adjustment screw lock nut, and turn adjustment screw to give a
clearance of .004 inches on both valves. When this figure is correct, tighten
rocker lock nut and check gap. Check valve clearance when engine is cold
(Fig. 7–52).
7–1.14 Adjustment Of Decompressor
1. Turn decompressor ratchet in a clockwise direction until lock engages with

ratchet teeth. Turn in decompressor adjustment until it touches
decompressor cam and then turn in adjustment a third of a turn only. Set lock B–02375
just toughing block and make sure that lock is lined with ratchet wheel teeth. Fig. 7–52 Valve Adjustment
Tighten locknut (Fig. 7–53).
7–1.15 Fuel Pump Installation
1. Check that fuel pump cam is at bottom of its stroke by turning crankshaft until
exhaust or inlet valve is open. Install fuel pump shims. Move stop/run lever

until groove in governor rack is in center of fuel pump aperture in crankcase
(Fig. 7–54).
2. Fuel pump rack can now be moved so that rack ball is in center position, then
install pump, checking that ball has engaged with governor rack. Check that
mark on pump flange lines up with center hole in crankcase. Tighten nuts
(Fig. 7–55).
7–1.16 Fuel Filter Assembly
1. Install new filter element. Do not

clean oil filter element.
7–1.17 Fuel And Oil Filter Assembly
1. Install new filter element. Check

relief valve and valve seat. When
worn or damaged the oil filter head
assembly must be installed new.
2. Install fuel and lube oil filter

B–02341
assemblies. Connect fuel pipes,
pump to filter. Install fuel tank and Fig. 7–53 Adjusting Decompressors
fuel pipe tank to filter. Tighten bolts
of each filter head to 10 ft.–lbs.
(1,39 Kgfm). The filter head
gaskets must be new.
3. Wash out fuel tank with clean fuel

oil. Install tank and pipe from tank
to fuel filter. Check that fuel line is
air free to fuel pumps.
7–1.18 Timing The Engine
1. To time the engine, perform the

timing on one cylinder at a time. No.
1 cylinder is at gear end. Timing of
fuel pump must be done only when
engine is cold. Move the stop/run
lever to middle position. Fig. 7–54 Install Fuel Pump Fig. 7–55 Injector Pump Alignment
600, 600D, 610, 611 Loader

2. Remove discharge union from pump (Fig. 7–56).
3. Lift out delivery valve and spring peg and put them in a container of clean
fuel (Fig. 7–57).
NOTE: Do not move delivery valve seat or joint washer.
4. Install union body, leaving out delivery valve and spring peg. Install short spill
pipe. Turn flywheel until it is a quarter of a turn before T.D.C. on compression
stroke. Pour fuel into fuel tank. A stream of fuel will now flow from fuel pump.
Turn flywheel slowly by hand, in normal running direction until flow from the
fuel pump stops.
5. Check for correct flywheel position at time which this happens. Position is
known as spill point. When flywheel is in correct position where flow stops,
the approximate timing marks before the T.D.C. mark on the flywheel, must
be in line with hole in bell–housing.
C–02104
6. When timing mark indicates position before bell–housing hole, add shims
between fuel pump and crankcase until correct. When timing indicates Fig. 7–56 Remove Discharge Union
position after bell–housing hole, remove shims to obtain correct timing (Fig.
7–58).
7. Assemble fuel injection equipment, including fuel delivery valve and spring.
Make sure that union body and sealing ring is fitted correctly. Tighten union
to 45 ft.–lbs. (6,2 m/Kgf).

7–1.19 Injector Installation
1. Set injectors to a pressure of 3250 lbs. sq. in (228,5 Kfg/cm Sq.). To make
adjustment of release pressure, loosen spring adjustment screw lock nut.
Turn adjustment screw clockwise to increase pressure, and
counterclockwise to decrease. Tighten lock nut (Fig. 7–59).
2. Install injectors. Check that sealing washers are in good condition. The
fastening nuts must be tightened to 15 ft.–lbs. (2,07 Kgfm).
3. Install rocker box covers. Install cylinder housing, and tighten fuel tank
fastening nuts and bolts.
A–02330
Fig. 7–57 Disassembling Pump
C–02096 C–02095
Fig. 7–58 Fuel Pump Shims Fig. 7–59 Injector Adjustment
600, 600D, 610, 611 Loader
7–2 TECHNICAL DATA (Fits, Clearances & Torques)
610,611ServiceManual#6556276–PetterEngineServiceSection
Camshaft End Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003–0.015

Crankshaft End Float (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0075–0.0185
Crankshaft End Float (not to exceed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.025
Crankshaft Out–Of–Round (not to exceed) . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003
Cylinder Bore Wear (not to exceed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010
Piston Ring Gap (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010–0.015
Piston Ring Gap (not to exceed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040
Exhaust Valve Lift by Decompressor (maximum) . . . . . . . . . . . . . . . . . . . . . 0.025
Bumping Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.032–0.037
Valve Rocker Clearance (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004
Main Bearing Clearance (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0012–0.0028
Connecting Rod Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . 0.0015–0.0030
Connecting Rod Small Bushing Diameter (installed) . . . . . . . . . . 1.1253–1.1258
Valve Depth From cylinder Head Face (new) . . . . . . . . . . . . . . . . . . 0.028–0.053
Valve Guide Bore Diameter (installed) . . . . . . . . . . . . . . . . . . . . . . 0.3125–0.3134
Cylinder Reboring Diameters:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5000–3.5010
Oversize:
0.020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5200–3.5210
0.040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5400–3.5410
Crankshaft Regrinding Diameters:
Main Journal Intermediate Journal Crankpin

Standard 2.9995/2.9990 2.74585/2.7480 2.1250/2.1245
Undersize:
0.010 2.9895/2.9890 2.7385/7.7380 2.1150/2.1145
0.020 2.9795/2.9790 2.7285/2.7280 2.1050/2.1045
0.030 2.9695/2.9690 2.7185/2.7180 2.0950/2.0945
0.040 2.9595/2.9590 2.7085/2.7080 2.0850/2.0845
Torque Wrench Settings:

Connecting Rod Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ft.–lbs.
Cylinder Head Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 ft.–lbs.
Injector Mounting Stud Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ft.–lbs.
Lubricating Oil Filter Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ft.–lbs.
Fuel Filter Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ft.–lbs.
Flywheel Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ft.–lbs.
Crankshaft Gear Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ft.–lbs.
Camshaft Gear Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ft.–lbs.
Flywheel End Extension Shaft Screw . . . . . . . . . . . . . . . . . . . . . . . . . 25 ft.–lbs.
Camshaft Extension Shaft Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ft.–lbs.
Rocker Support Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ft.–lbs.
Center Main Bearing Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ft.–lbs.
600, 600D, 610, 611 Loader

SPECIFICATIONS
Paragraph Page WISCONSIN
Number Number
ENGINE SPECIFICATIONS
(WISCONSIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–1
DEUTZ
(DEUTZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–1
(PETTERS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–1
PETTER
MOTOR SPECIFICATIONS
(ELECTRIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D–1
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–1

ELECTRIC
TECHNICAL
DATA

SPECIFICATIONS
600, 600D, 610, 611 Loader

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ENGINE SPECIFICATIONS (WISCONSIN)
Paragraph Page WISCONSIN
Number Number
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–1 8A–1
LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–3
600, 600D, 610, 611 Loader

173 of Dec.
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174 of 214 –8A–0 Service Manual
8A TECHNICAL DATA
8A–1 ENGINE SPECIFICATIONS (Wisconsin)
All specifications are given in inches with metric parentheses.
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.7 cu. in. (1,76 liters)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 (82,55 liters)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 (82,55 liters)
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3–4–2
Oil Capacity W/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 gal. (3,79 liters)
Maximum RPM (Full Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2800 RPM
Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 RPM
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 4–5 PSI (27,6–34,5 kPa) (Normal)–
15 PSI (103,4 kPa) (Maximum)
Fuel Pump Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3 PSI (13,8–20,7 kPa)
8A–1.1 Fuel Specifications
Always use clean fuel. Do not let the fuel tank become empty.
Type of Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regular gasoline 85–90 octane
8A–1.2 Engine Oil
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 marks on the dipstick.
Specifications:
Use a good quality detergent motor oil that meets the correct API service
classification.
Use oil of proper SAE viscosity for expected temperature conditions at the time
of starting, not for the highest temperature expected during the working day.
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
F°–30 –20 –10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120 +130 +140

Use summer recommendations in winter if machine is kept in warm building.
600, 600D, 610, 611 Loader

175 of 214 –8A–1– Service Manual
Revised March 80
8A–1.3 Valve Mechanism
Valve Stem Clearance in Guide . . . . . . . . . . . . . . . . . . . . . . . .003 (0,076–0,127)
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .007 (0,178)
Valve Tappet Clearance:
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .008 (0,203)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .016 (0,406)
8A–1.4 Crankshaft
Crank Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . 1.875–1.876 (47,625–47,650)
Crank Pin Length . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.130–1.135 (28,702–28,829)
Crankshaft End Play (Cold) . . . . . . . . . . . . . . . . . . . . . . .002–.004 (0,051–0,102)
8A–1.5 Idler Gear
Idler Gear to Shaft Collar Clearance . . . . . . . . . . .0015–.0035 (0,0381–0,0889)
8A–1.6 Connecting Rod
Connecting Rod to Crank Pin Clearance (Diameter) .0012–.0033 (0,030–0,086)
Connecting Rod to Crank Pin Clearance
(Side Clearance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .009–.018 (0,229–0,457)
Connecting Rod Busing to Piston Pin Clearance . . .0005–.0011 (0,013–0,028)
8A–1.7 Piston, Piston Pin, Piston Rings
Piston to Cylinder at Piston Skirt (Wide Skirt) . . . . . .0035–.0040 (0,089–0,102)

Piston Pin to Piston clearance . . . . . . . . . . . . . . . . . . .0000–.0008 (0,000–0,020)
Piston Ring Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010–.020 (0,254–0,508)
Piston Ring Side Clearance in Grooves:
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .002–.0035 (0,051–0,089)
2nd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .001–.0025 (0,025–0,064)
3rd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .001–.0025 (0,025–0,064)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0025–.004 (0,064–0,101)
8A–1.8 Ignition System
Breaker Point Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .018–.022 (0,458–0,559)
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .030 (0,762)
8A–1.9 Distributor Advance Characteristics
VH4D The distributor has an automatic advance. The automatic advance is
11–1/2° in the distributor, equal to 23° on the crankshaft. The distributor is fully
advanced at 1800 RPM engine speed or above.
VF4D The distributor has an automatic advance. The automatic advance is
13–1/2° in the distributor, equal to 27° on the crankshaft. The distributor is fully
advanced at 1800 RPM engine speed or above.
8A–1.10 Starter
the starter is the gear drive type and is 12 volt, negative ground.
8A–1.11 Engine Torque Specifications
Item Ft.–Lbs. 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
600, 600D, 610, 611 Loader

176 of 214 –8A–2 Service Manual
Revised February 80
600 LOADER (WISCONSIN GAS)
138 55.1
(3505) (1399.51)
120
38° (3048)
65
108 (1651)
81.7 17.75 (2743)
(2075) (450)
31
101
(787)
(2565) 41.5
86 (1054
(2184) )
60 45°
(1524) 48
(1219)
41
(1041)
34
27°
8 (203) 8 (203) 25° (864)
35 15 46
(889) (381) (1168)
79 53
(2007) (1359)

107
(2718) PI–01458
Dimensions are given for loader equipped with dirt bucket Where applicable, specifications conform to
and may vary with other bucket types. All dimensions are ICED & SAE standards and are subject to
shown in inches. Metric dimensions are given in millimeters change without notice.
enclosed by parentheses.
OPERATIONAL & PERFORMANCE LOADER HYDRAULICS
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine driven, gear type
Operating Weight . (Gasoline) 3625 (1645 kg) (LP Gas) 3695 (1677 kg) Minimum Pump Capacity . . . . . . . . . . 9.5 GPM (35,95L/M) @ 2400 RPM
Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . . 1000 lbs. (453,6 kg) System Relief Setting . . . . . . . . . . . . . . . . . . . . . . . 1700 PSI (11721 kPa)
Lift Capacity to Maximum Height . . . . . . . . . . . Gas 1700 lbs. (771,8 kg) Filtration . . . . . Full flow on suction port of pump with by–pass, condition
LP Gas 1700 lbs. (771,8 kg) indication & 33 micron replaceable paper element
Tipping Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas 1880 lbs. (853,3 kg) Cylinders . . . . . . . . . . . . . . . . . Doubleacting w/ Teflon seals & wear rings
LP Gas 1990 lbs. (903,4 kg) Function Lift Tilt
Hydraulic Function Time: Bore Diameter 2’’ (50,8 mm) 2’’ (50,8 mm)
Raise to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 sec. Rod Diameter 1.25’’ (31.75 mm) 1’’ (25,4 mm)
Lower from Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 sec. Stroke 25’’ (635 mm) 16’’ (406,4 mm)
Dumping Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 sec. Valves . . . . . . . . . . . . . . . . . . . . Open–center type with float detent on lift
Rollback Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 sec.
Travel Speed . . . . . . . . . Infinitely variable to 5.7 MPH forward & reverse ELECTRICAL
Controls: Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 amp. enclosed belt driver.
Vehicle . . . . . . . . . . . . . . . . . . . . . Forward, reverse & steering functions Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 amp.–hr. rating 12 volt
controlled by two hand levers Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt gear drive
Travel Speed . . . . . . . Hand lever controlled, adjusted variable sheave. DRIVE SYSTEM
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift, tilt & auxiliary functions Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable sheave type
controlled by separate foot pedals. Clutches . . . . . . . . . . . . . . 4 (2 each side) single disc pressure lubricated
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handle lever throttle, manual Primary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1
choke & key–type ignition–starter switch. Secondary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00:1
ENGINE Final Drive . . . . #60H roller chain running in sealed oil bath (2.92:1 ratio)
Total Engine to Wheel Reduction . . . . . . . . . Variable from 37:1 to 100:1
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wisconsin CAPACITIES
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VF4D Fuel . . . . . . . . . (Gasoline) 10 gal. (37,85 L) (LP Gas) 33 lbs. (14,98 kg)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline or LP Gas Engine Lubricant Including Filter . . . . . . . . . . . . . . . . . . . . . . . 4 qt. (3,8 L)
Governed Flywheel Horsepower . . . . . . . . . . 25 (18,6 kw) @ 2400 RPM Hydraulic Reservoir & Final Drive Case . . . . . . . . . . . . . . 17 gal. (75,7 L)
Maximum Torque . . . . . . . . . . . . . . 57.5 ft.–lbs. (77,9 Nm) @ 1800 RPM Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 gal. (75,7 L)
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 TIRES
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25x3.25 (82,5x82,5) Standard . . . . . . . . . . . Melroe special bar 7:00x15–6 ply steel cap nylon
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.7 cubic inches (1,8L) Pressure . . . . . . . . . . . . . . . . . . . . . . . 45–50 PSI (310,275–344,750 kPa)
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt distributor COUNTERWEIGHT
Cooling Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Standard Cast Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 lbs. (45,4 kg)
Lubrication Filtration . . . . . . . Replacement element, full flow w/by–pass MACHINE WEIGHT (Less Bucket)
Crankcase Ventilation . . . . . . . . . Internal breathing w/sealed carburetor Shipping (Gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3170 lbs. (1439 kg)
Air Cleaner . . . . . . Replaceable dry cartridge type w/condition indicator Shipping (LP Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3280 lbs. (1489 kg)
600, 600D, 610, 611 Loader

177 of 214
Revised February 80 –8A–3– Service Manual
610 LOADER (WISCONSIN GAS)
610,611ServiceManual#6556276–Specifications(Wisconsin)SectionPart1of5
138 55.1
(3505) (1399.51)
120
38° (3048)
65
108 (1651)
81.7 17.75 (2743)
(2075) (450)
31
101
(787)
(2565) 41.5
86 (1054
(2184) )
60 45°
(1524) 48
(1219)
41
(1041)
34
27°
8 (203) 8 (203) 25° (864)
35 46
15
(889) (1168)
(381)
79 53
(2007) (1359)

107
(2718) PI–01458
and may vary with other bucket types. All dimensions are IDEC & SAE standards and are subject to
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine driven, gear type
Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 lbs. (1800 kg) Minimum Pump Capacity . . . . . . . . . . . 11 GPM (41,6 L/M) @ 2800 RPM
Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . . 1000 lbs. (453,6 kg) System Relief Setting . . . . . . . . . . . . . . . . . . . . . . . 1700 PSI (11721 kPa)
Lift Capacity to Maximum Height . . . . . . . . . . . . . . . . . 2190 lbs (990 kg) Filtration . . . . . . . . . . . . Full flow on suction side with by–pass, condition
Tipping Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 lbs. (771,1 kg) indication & 33 micron element
Hydraulic Function Time: Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doubleacting
Raise to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 sec. Function Lift Tilt
Lower from Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 sec. Bore Diameter 2’’ (50,8 mm) 2’’ (50,8 mm)
Dumping Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 sec. Rod Diameter 1.25’’ (31.75 mm) 1’’ (25,4 mm)
Rollback Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 sec. Stroke 25.90’’ (637,86 mm) 16.50’’ (419,10 mm)
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . Infinitely variable to 6.6 MPH Valves . . . . . . . . . . . . . . . . . . . . Open–center type with float detent on lift
(10,6 kg/hr)forward & reverse ELECTRICAL
Controls: Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosed belt driven 22 amp.
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forward, reverse & steering Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt 70 amp.–hr. rating
functions controlled by two hand levers Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt gear drive
Travel Speed . . . . . . . . . . . . . . . . . . Hand lever controlled, hydraulically DRIVE SYSTEM
adjusted variable sheave. Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable sheave type
Loader Lift, tilt & auxiliary functions controlled by separate foot pedals. Clutches . . . . . . . . . . . . . . 4 (2 each side) single disc pressure lubricated
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handle lever throttle, manual Primary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1 ratio
choke & key–type ignition–starter switch. Secondary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00:1 ratio
Final Drive . . . . . . . . . . . . . . . #60H roller chain running in sealed oil bath
ENGINE Total Engine to Wheel Reduction . . . . . Variable from 37:1 to 100:1 ratio
CAPACITIES
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wisconsin Fuel . . . . . . . . . . . . . (Gasoline) 11 gal (41,6 L) (LP Gas) 33 lbs. (15 kg)
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VF4D Engine Lubricant Including Filter . . . . . . . . . . . . . . . . . . . . . . . 4 qt. (3,8 L)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline or LP Gas Hydraulic Reservoir & Final Drive Case . . . . . . . . . . . . . . 17 gal. (64,4 L)
Governed Flywheel Horsepower . . . . . . . . . . . . 30 (22 kw) @ 2800 RPM Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 gal. (75,7 L)
Maximum Torque . . . . . . . . . . . . . . . . 66.2 ft.–lbs. (90 Nm) @ 1800 RPM TIRES
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:00x15–6 ply steel cap nylon
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . 3.25x3.25 in. (82,5x82,5 mm) Pressure . . . . . . . . . . . . . . . . . . . . . . . 45–50 PSI (310,275–344,750 kPa)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.7 cubic inches (1,8L) COUNTERWEIGHT
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt breaker Standard Cast Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 lbs. (45,4 kg)
Cooling Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 lbs. (140 kg)
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Spray MACHINE WEIGHT (Less Attachments)
Lubrication Filtration . . . . . . . Replacement element, full flow w/by–pass Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline: 3575 lbs. (1621,6 kg)
Crankcase Ventilation . . . . . . . . . Internal breathing w/sealed carburetor LP Gas: 3645 lbs. (1653,4 kg)
Air Cleaner . . . . . . Replaceable dry cartridge type w/condition indicator
600, 600D, 610, 611 Loader
178 of 214 80
Revised February –8A–4 Service Manual
ENGINE SPECIFICATIONS (DEUTZ)
Paragraph Page
Number Number
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–1 8B–1
LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–4
DEUTZ
600, 600D, 610, 611 Loader

179 of Dec.
Added 214 78 –8B––1– Service Manual
600, 600D, 610, 611 Loader

180 of 214 –8B–0 Service Manual
8B–1 ENGINE SPECIFICATIONS (Deutz F2L 411)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.2 cu. in. (1,39 liters)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61 (91,95 L)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13 (104,90 L)
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
Oil Capacity W/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 gal. 3,79 liters)
8B–1.2 Fuel System
Pressure of Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . 4–5 PSI (27,5–34,5 kPa)
Make of Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . Bosch PFR2K70A414/2
Make of Fuel Injection Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DLLA 152S533
Release Pressure of Injection Nozzle New–2560–2673 PSI (17649–18428 kPa)
Used–2488–2602 PSI (17152–17938 kPa)
Injection timing (Start of Injection) . . . . . . . . . . . . . . . . . . . . . . . . . . . 25° B.T.D.C.
Distance from Injection Pump Mounting Flange to Camshaft Base Circle
Including gasket and shims . . . . . . . . . . . . . . . . . . 3.248–3.256 (82,5–82,7 mm)
8B–1.2 Lubrication System
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 28.5 PSI (196,5 kPa) at 1500 RPM
End Clearnace in Oil Pump Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .004 (,1 mm)
Check oil level after every 8 hours of operation. (Check oil every 4 hours on new

Oil leverl must be maintained between the add and full mark on the dipstick. Use
a good quality detergent motor oil that meets the api service classificatin CC or
CD.

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
F°–30 –20 –10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120 +130 +140

600, 600D, 610, 611 Loader

181 of 214 –8B–1– Service Manual
Revised February 80
8B–1.3 Govern, Front Cover and Throttle
Distance from Governor Bearing Cup to Engine Block . . 3.37–3.38 (85,6–85,7)
End Play in Throttle Shaft . . . . . . . . . . . . . . . . . . . . . . . . .008–.043 (0,2–1,1 mm)
Engine High Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2674 RPM
Engine Low Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 RPM
8B–1.4 Cylinder Head and Valves
I.D. of Valve Guides . . . . . . . . . . . . . . . . . . . . . . . .315–.3155 (8,000–8,015 mm)
I.D. of Bore for Intake Valve Seat . . . . . . . . . . . . . 1.378–1.379 (35,000–35,025)
I.D. of Bore for Exhaust Valve Seat . . . . . . . . . 1.5354–1.5364 (39,000–39,025)
Valve Seat Width, Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .040–.055 (1,0–1,4)
Valve Seat Width, Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . .031–.033 (0,8–0,83
Valve Seat Angle, Exhaust and Intake . . . . . . . . . . . . . . . . . . . . . 44–1/2° ± 0° 10’
Valve Stem Diameter, Intake . . . . . . . . . . . . . . . . . . . . .3134–.314 (7,96–7,975)
Valve Stem Diameter, Exhaust . . . . . . . . . . . . . . . . . . . . .3118–.3126 (7,92–7,94)
Maximum Distance Valves may be Recessed into Head . . . . . . . .020 (0,5 mm)
Maximum Distance Valves may Protrude from Head, Exhaust . . . . . .095 (2,42)
Valve Clearance, Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 (0,15 mm)
Minimum Free Length of Valve Springs . . . . . . . . . . . . . . . . . . . . . . 1.81 (46 mm)
Maximum Length of Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.114 (231,5)
8B–1.5 Cylinder, Piston and Connecting Rod
Cylinder Bore (Standard) . . . . . . . . . . . . . . . . . . . . 3.622–3.623 (92,000–92,022)
Maximum Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .012 (0,3 mm)
Piston Diameter (Standard) . . . . . . . . . . . . . . . . . 3.6197–3.620 (91,940–91,949)
Piston Diameter (1st oversize) . . . . . . . . . . . . . 3.6394–3.6397 (92,440–92,449)
Piston Diameter (2nd oversize) . . . . . . . . . . . . . . 3.659–3.6594 (92,940–92,949)

Wrist Pin Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1812–1.1814 (30,002–30,007)
Wrist Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . 1.1809–1.1811 (29,996–30,00)
Piston Ring Side Clearance, Top Compression Ring . . . . . . . . . . . (0,088–0,112)
Piston Ring Side Clearance, 2nd & 3rd Compression Ring . . . . . (0,090–0,122)
Piston Ring Side Clearance, Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . .006 (0,15)
Ring End Gap, Compression . . . . . . . . . . . . . . . . . . . . .014–.022 (0,35–0,55 mm)
Maximum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .079 (2,0 mm)
Distance Between Piston & Head . . . . . . . . . . . . . . . . . . . . . . .031–.039 (0,8–1,0)
Compression Pressure . . . . . . . . . . . . . . . . . . . . . 355–575 PSI (2445–3960 kPa)
NOTE: The cylinders must be within 35 PSI (241 kPa) of each other.
I.D. of Hole in Connecting Rod for Wrist
Pin Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3386–1.3392 (34,000–34,016)
I.D. of Wrist Pin Bushing . . . . . . . . . . . . . . . . . . 1.1827–1.1841 (30,040–30,076)
I.D. of Hole in Connecting Rod for
Crankshaft Bearing . . . . . . . . . . . . . . . . . . . . . . 2.2441–2.2448 (57,000–57,019)
Rod–to–Crankshaft Clearance . . . . . . . . . . . . . . . . . . .002–.0044 (0,050–0,112)
Rod–to–Crankshaft (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .012 (0,3)
Rod–to–Crankshaft Side Clearance . . . . . . . . . . . . . . . .006–.012 (0,170–0,271)
8B–1.6 Camshaft, Crankshaft, Bearings
Camshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .006–.024 (0,15–0,60)
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .039 (1,0)
I.D. of Camshaft Bushing . . . . . . . . . . . . . . . . . . . 1.8901–1.8923 (48,01–48,064)
Diameter of Crankpin, Standard . . . . . . . . . . . . . 2.046–2.0468 (51,971–51,990)
Diameter of Crankpin, 1st Undersize . . . . . . . . 2.0264–2.0272 (51,471–51,490)
Diameter of Crankpin, 2nd Undersize . . . . . . . 2.0067–1.0075 (50,971–50,990)
Diameter of Crankpin, 3rd Undersize . . . . . . . . 1.9870–1.9878 (50,471–50,490)
Width of Crankpin . . . . . . . . . . . . . . . . . . . . . . . . 1.3386–1.3401 (34,000–34,039)
Diameter of Crankshaft Main Journals
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4398–2.4406 (61,971–61,990)
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
600, 600D, 610, 611 Loader
182 of 214 –8B–2 Service Manual
8B–1.7 Torque Specifications
ITEM PRELOADING TIGHTENING TOTAL

Cylinder Head Bolts 21.5 ft.–lbs. (29 Nm) 30° 60° 60° 150°
Injector Hold–Down 21.5 ft.–lbs. (29 Nm) 60° 60° –– 120°
Connecting Rod 21.5 ft.–lbs. (29 Nm) 30° 60° –– 90°
Camshaft Bearing
Flange –– –– –– –– 25 ft.–lbs. (34 Nm)
Bearing Support 21.5 ft.–lbs. (29 Nm) 30° 30° –– 60°
Blower Mounting Bolts –– –– –– –– 25 ft.–lbs. (34 Nm)
V–Belt Pulley 21.5 ft.–lbs. (29 Nm) 90° –– –– 90°
Intake Manifold –– –– –– –– 11 ft.–lbs. (15 Nm)
Crankshaft Gear 21.5 ft.–lbs. (29 Nm) 30° 30° –– 60°
Oil Suction Pipe –– –– –– –– 36 ft.–lbs. (49 Nm)
Flywheel 21.5 ft.–lbs. (29 Nm) 60° 30° –– 90°
Rocker Arm Bolts 21.5 ft.–lbs. (29 Nm) 45° –– –– 45°

Balance Weight 21.5 ft.–lbs. (29 Nm) 30° 30° –– 60°
8B–1.8 Special Tools (Also See Clark Tool Catalog P/N 6556519)
DEUTZ P/N DESCRIPTION

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
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
600, 600D, 610, 611 Loader

183 of 214 –8B–3– Service Manual
Added Dec. 78
600D LOADER (DEUTZ DIESEL)
138 54
(3505) (1372)
120
38° (3048)
65
108 (1651)
81.7 17.75 (2743)
(2075) (450)
31
101
(787)
(2565) 41.5
86 (1054
(2184) )
60 45°
(1524) 48
(1219)
41
(1041)
34
27°
8 (203) 8 (203) 25° (864)
35 15 46
(889) (381) (1168)
79 53.5
(2007) (1359)

107
(2718) PI–01458
Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4235 (1921,0 kg) Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine driven, gear type
Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . . 1000 lbs. (453,6 kg) Minimum Pump Capacity . . . . . . . . . . . . 8.7 GPM (33L/M) @ 2700 RPM
Lift Capacity to Maximum Height . . . . . . . . . . . . . . . 1700 lbs. (771,1 kg) System Relief Setting . . . . . . . . . . . . . . . . . . . . . . . 1700 PSI (11721 kPa)
Tipping Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1830 lbs. (830,1 kg) Filtration . . . . . . . . . . . . Full flow on suction side with by–pass, condition
Hydraulic Function Time: indicator & 33 micron replaceable element
Raise to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 sec. Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doubleacting
Lower from Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 sec. Function Lift Tilt
Dumping Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 sec. Bore Diameter 2.00’’ (50,80 mm) 2.00’’ (50,80 mm)
Rollback Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 sec. Rod Diameter 1.25’’ (31,75 mm) 1.00’’ (25,4 mm)
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . Infinitely variable to 4.4 MPH Stroke 25.90’’ (658,00 mm) 16.60’’ (422,00 mm)
(7,1 km/hr) forward & reverse Valves . . . . . . . . . . . . . . . . . . . . Open–center type with float detent on lift
Controls:
Vehicle . . . . . . . . . . . . . . . . . . . . . Forward, reverse & steering functions ELECTRICAL
controlled by two hand levers Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosed belt driver 22 amp.
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand elver controlled, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt 70 amp.–hr. rating
hydraulically adjusted variable sheave. Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt gear drive
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift, tilt & auxiliary functions DRIVE SYSTEM
controlled by separate foot pedals. Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable sheave type
Engine . . . . . . . . . . . . . . . . . . . . . Handle lever throttle, key–type starter Clutches . . . . . . . . . . . . . . 4 (2 each side) single disc pressure lubricated
switch & pushbutton preheater. Primary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45:1 ratio
Secondary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00:1 ratio
ENGINE Final Drive . . . . . . . . . . . . . . #60H roller chain running in sealed oil bath
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deutz Total Engine to Wheel Reduction . . . . . Variable from 37:1 to 100:1 ratio
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2L410 CAPACITIES
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 gal (39,7 L)
Governed Flywheel Horsepower . . . . . . . . . . 24 (30,5 kw) @ 2700 RPM Engine Lubricant Including Filter . . . . . . . . . . . . . . . . . . . . . . . 4 qt. (3,8 L)
Maximum Torque . . . . . . . . . . . . . 47.4 ft.–lbs. (64,27 Nm) @ 2200 RPM Hydraulic Reservoir & Final Drive Case . . . . . . . . . . . . . . 17 gal. (64,4 L)
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 gal. (75,7 L)
Bore/Stroke . . . . . . . . . . . . . . . . . . . . 3.59x3.94 in. (91,186x100,076 mm) TIRES
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77.6 cubic inches (1,3L) Standard . . . . 7:00x15–6 ply nylon steel cap w/Melroe special bar tread
Cooling Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Pressure . . . . . . . . . . . . . . . . . . . . . . . 45–50 PSI (310,275–344,750 kPa)
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure COUNTERWEIGHT
Lubrication Filtration . . . . . . . Replacement element, full flow w/by–pass Standard Cast Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 lbs. (45,4 kg)
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . Filtered Road Vent Ballast (If Any) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 lbs. (140 kg)
Air Cleaner . . . . . . Replaceable dry cartridge type w/condition indicator MACHINE WEIGHT (Less Bucket)
Preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt glow plug Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3805 lbs. (1726,0 kg)
600, 600D, 610, 611 Loader

184 of 214 80
Revised February –8B–4 Service Manual
611 LOADER (DEUTZ DIESEL)
138 54
(3505) (1372)
120
38° (3048)
65
108 (1651)
81.7 17.75 (2743)
(2075) (450)
31
101
(787)
(2565) 41.5
86 (1054
(2184) )
60 45°
(1524) 48
(1219)
41
(1041)
34
27°
8 (203) 8 (203) 25° (864)
35 46
15
(889) (1168)
79 (381) 53.5
(2007) (1359)

107
(2718) PI–01458
Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4200 (1900 kg) Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine driven, gear type
Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . . 1000 lbs. (453,6 kg) Minimum Pump Capacity . . . . . . . . . . . . . 8.7 GPM (32,1L) @ 2700 RPM
Tipping Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2100 lbs. (950 kg) Filtration . . . . . . . . . . . . Full flow on suction side with by–pass, condition
Hydraulic Function Time: indicator & 33 micron replaceable paper element
Controls:
controlled by two hand levers Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosed belt driver 22 amp.
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand elver controlled, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt 70 amp.–hr. rating
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift, tilt & auxiliary functions DRIVE SYSTEM
controlled by separate foot pedals. Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable sheave type
Engine . . . . . . . . . . . . . . . . . . . . . Handle lever throttle, key–type starter Clutches . . . . . . . . . . . . . . 4 (2 each side) single disc pressure lubricated
switch & pushbutton preheater. Primary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45:1 ratio
Secondary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00:1 ratio
ENGINE Final Drive . . . . . . . . . . . . . . #60H roller chain running in sealed oil bath
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deutz Total Engine to Wheel Reduction . . . . . Variable from 37:1 to 100:1 ratio
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2L411 CAPACITIES
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 gal (26 L)
Governed Flywheel Horsepower . . . . . . . . . 27.5 (20,5 kw) @ 2700 RPM Engine Lubricant Including Filter . . . . . . . . . . . . . . . . . . . . . . . 4 qt. (3,8 L)
Maximum Torque . . . . . . . . . . . . . . . . . 58 ft.–lbs. (79 Nm) @ 2000 RPM Hydraulic Reservoir & Final Drive Case . . . . . . . . . . . . . . 17 gal. (64,4 L)
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 gal. (75,7 L)
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . 3.62x4.13 in. (91,95x104,90 mm) TIRES
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . 85.2 cubic inches (1,396 L) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:00x15–6 ply nylon steel cap
Cooling Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Pressure . . . . . . . . . . . . . . . . . . . . . . . 45–50 PSI (310,275–344,750 kPa)
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . Filtered Road Vent Ballast (If Any) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 lbs. (140 kg)
Preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt glow plug Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3800 lbs. (1700 kg)
600, 600D, 610, 611 Loader

185 of 214
Revised February 80 –8B–5– Service Manual
611D LOADER (BUREAU OF MINES APPROVED)
610,611ServiceManual#6556276–Specifications(Deutz)SectionPart2of5
135.5 54
(3442) (1372)
120
38° (3048)
65
108 (1651)
82 17.50 (2743)
(2083) (445)
31
101
(787)
(2565) 42
86 (1067)
(2184)
60.25 45°
(1530) 51.25
(1302)
41
(1041)
34
21°
8 (203) 87.5(191) 25° (864)
35 46
15
(889) (1168)
84.25 (381) 53.5
(2140) (1359)

108.25
(2750) PI–01458
Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4326 (1962,0 kg) Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine driven, gear type
Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . . 1000 lbs. (453,6 kg) Minimum Pump Capacity . . . . . . . . . . . 8.7 GPM (33,1 L/M @ 2700 RPM
Tipping Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2560 lbs. (1161 kg) Filtration . . . . . . . . . . . . Full flow on suction side with by–pass, condition
(10 km/hr) forward & reverse Valves . . . . . . . . . . . . . . . . . . . . Open–center type with float detent on lift
Controls: ELECTRICAL
Vehicle . . . . . . . . . . . . . . . . . . . . . Forward, reverse & steering functions Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . Enclosed belt driver 22 amp.
controlled by two hand levers Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt 70 amp.–hr. rating
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand lever controlled, Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt gear drive
hydraulically adjusted variable sheave. DRIVE SYSTEM
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift, tilt & auxiliary functions Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable sheave type
controlled by separate foot pedals. Clutches . . . . . . . . . . . . . . 4 (2 each side) single disc pressure lubricated
Engine . . . . . . . . . . . . . . . . . . . . . Handle lever throttle, key–type starter Primary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45:1 ratio
switch & pushbutton preheater. Secondary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00:1 ratio
Final Drive . . . . . . . . . . . . . . #60H roller chain running in sealed oil bath
ENGINE Total Engine to Wheel Reduction . . . . . Variable from 37:1 to 100:1 ratio
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Deutz CAPACITIES
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2L411W Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 gal (30 L)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Diesel Engine Lubricant Including Filter . . . . . . . . . . . . . . . . . . . . . . . 4 qt. (3,8 L)
Governed Flywheel Horsepower . . . . . . . . . 22.5 (16,8 kw) @ 2700 RPM Hydraulic Reservoir & Final Drive Case . . . . . . . . . . . . . . 17 gal. (64,4 L)
Maximum Torque . . . . . . . . . . . . . . . . . 53 ft.–lbs. (72 Nm) @ 2200 RPM Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 gal. (75,7 L)
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TIRES
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . 3.62x4.13 in. (91,9x104,90 mm) Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10x16.5–6 ply
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . 85.2 cubic inches (1,396 L) Pressure . . . . . . . . . . . . . . . . . . . . . . . 30–35 PSI (206,850–241,325 kPa)
Cooling Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air COUNTERWEIGHT
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Front Mounted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 lbs. (77,1 kg)
Lubrication Filtration . . . . . . . Replacement element, full flow w/by–pass Scrubber Muffler Filled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . Filtered Road Vent Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner . . . . . . Replaceable dry cartridge type w/condition indicator MACHINE WEIGHT (Less Attachments)
Preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt glow plug Shipping (W/Scrubber Muffler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
600, 600D, 610, 611 Loader

186 of 214 80
Revised February –8B–6 Service Manual
ENGINE SPECIFICATIONS (PETTER)
Paragraph Page
Number Number
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–1 8C–1
LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–6
PETTER
600, 600D, 610, 611 Loader

187 of Dec.
Added 214 78 –8C––1– Service Manual
600, 600D, 610, 611 Loader

188 of 214 –8C–0 Service Manual
8C–1 ENGINE SPECIFICATIONS (Petter)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 CID (1147 cc)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 (88,9)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.625 (92,1)
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Oil Capacity W/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1/2 gal. (5,2 L)
8C–1.1 Fuel Specifications
Always use clean fuel. Do not let the fuel tank become empty.
Type of Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Diesel Fuel
8C–1.2 Engine Oil
System:
Check oil level after every 8 hours of operation. (Check oil every 4 hours on new
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 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
F°–30 –20 –10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110 +120 +130 +140

Lubrication System
Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 PSI (310,27 kPa)
Lubrication Filtration . . . . . . . . . . . . . . Replaceable element, full flow w/by–pass
600, 600D, 610, 611 Loader

189 of 214 –8C–1– Service Manual
Revised February 80
8C–1.3 Cylinder Head
Valve Guide Bore Diameter . . . . . . . . . . . . . . . . . . . . 0.312–0.313 (7,924–7,950)
Valve Depth From Cylinder Head Face (New) . . . . 0.028–0.053 (0,711–1,346)
8C–1.4 Valve Mechanism
Valve Rocker Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 (0,101)
Exhaust Valve Lift By Decompressor (Max.) . . . . . . . . . . . . . . . . . . 0.025 (0,635)
Bumping Clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0.032–0.037 (0,812–0,939)
8C–1.5 Camshaft
Camshaft End Float . . . . . . . . . . . . . . . . . . . . . . . . . 0.003–0.015 (0,0762–0,381)
Intake Valve Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5° before TDC
Intake Valve Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.5° after BDC
Exhaust Valve Opens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.5° before BDC
Exhaust Valve Closes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5° after TDC
8C–1.6 Crankshaft
Crankshaft End Float (New) . . . . . . . . . . . . . . . 0.0075–0.0185 (0,1905–0,4699)
Crankshaft End Float (Not To Exceed) . . . . . . . . . . . . . . . . . . . . . . 0.025 (0,635)
Crankshaft Out–Of–Round (Not to Exceed) . . . . . . . . . . . . . . . . . 0.003 (0,0762)
Main Bearing Clearance (New) . . . . . . . . . . . . 0.0012–0.0028 (0,0304–0,07112)
Connecting Rod Bearing Clearance . . . . . . . . . 0.0015–0.0030 (0,0381–0,0762)
Crankshaft Regrinding Diameters:

Main Journal Intermediate Journal Crankpin
Standard 2.9995–2.990 2.7485–2.7480 2.1250–2.1245
(76,1863–76,1746) (69,8119–69,7992) (53,975–53,9623)
Undersize:
0.010 (0,254) 2.9895–2.9890 2.7385–2.7380 2.1150–2.1145
(5,9333–75,9206) (69,5579–69,5452) (53,721–53,7083)
0.020 (0,508) 2.9795–2.9790 2.7285–2.7280 2.1050–2.1045
(75,6793–75,6666) (69,3039–69,2912) (53,467–53,4543)
0.030 (0,762) 2.9695–2.9690 2.7185–2.7180 2.0950–2.0945
(75,4253–75,4126) (69,0499–69,0372) (53,213–53,2003)
0.040 (1,016) 2.9595–2.9590 2.7085–2.7080 2.0850–2.0845
(75,1713–75,1586) (68,7959–68,7832) (52,959–52,9463)
8C–1.7 Connecting Rod

Connecting Rod Bearing Clearance . . . . . . . . . 0.0025–0.0030 (0,0381–0,0762)
Connecting Rod Small Bushing Diameter
(Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1253–1.1258 (28,5826–28,5953)
8C–1.8 Piston
Piston Ring Gap (New) . . . . . . . . . . . . . . . . . . . . . . . . 0.010–0.015 (0,254–0,381)
Piston Ring Gap (Not To Exceed) . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 (1.016)
8C–1.9 Cylinder Block
Cylinder Bore Wear (Not To Exceed) . . . . . . . . . . . . 0.010–0.015 (0,254–0,381)
Cylinder Reboring Diameters:
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.500–3.501 (88,9–88,925)
Oversize:
0.20 (0,508) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5200–3.5210 (89,408–89,4334)
0.040 (1,016) . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5400–3.5410 (89,916–89,9414)
600, 600D, 610, 611 Loader

190 of 214 –8C–2 Service Manual
8C–1.10 Torque Specifications
Connecting Rod Cap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . 40 ft.–lbs. (54,233 Nm)
Cylinder Head Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 ft.–lbs. (46,098 Nm)
Injector Mounting Stud Nuts . . . . . . . . . . . . . . . . . . . . . . . 15 ft.–lbs (20,337 Nm)
Lubricating Oil Filter Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ft.–lbs. (13,558 Nm)
Fuel Filter Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ft.–lbs. (13,558 Nm)
Flywheel Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ft.–lbs. (47,454 Nm)
Crankshaft Gear Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ft.–lbs. (47,454 Nm)
Camshaft Gear Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ft.–lbs. (33,895 Nm)
Flywheel End Extension Shaft Bolt . . . . . . . . . . . . . . . . . . 25 ft.–lbs. (33,895 Nm)
Camshaft Extension Shaft Bolt . . . . . . . . . . . . . . . . . . . . . 35 ft.–lbs. (47,454 Nm)
Rocker Support Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 ft.–lbs (20,337 Nm)
Center Main Bearing Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ft.–lbs. (33,895 Nm)
600, 600D, 610, 611 Loader

191 of 214 –8C–3– Service Manual
Added Dec. 78
600D LOADER (DEUTZ DIESEL)
610,611ServiceManual#6556276–Specifications(Petter)SectionPart3of5
138 54
(3505) (1372)
120
38° (3048)
65
108 (1651)
81.7 17.75 (2743)
(2075) (450)
31
101
(787)
(2565) 41.5
86 (1054
(2184) )
60 45°
(1524) 48
(1219)
41
(1041)
34
27°
8 (203) 8 (203) 25° (864)
35 15 46
(889) (381) (1168)
79 53.5
(2007) (1359)

107
(2718) PI–01458
Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4255 (1930 kg) Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt driven, gear type
Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . . 1000 lbs. (453,6 kg) Minimum Pump Capacity . . . . . . . . . . . 8.7 GPM (33,0 L/M @ 3000 RPM
Tipping Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1830 lbs. (830,1 kg) Filtration . . . . . . . . . . . . Full flow on suction side with by–pass, condition
Rollback Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 sec. Rod Diameter 1.25’’ (31.75 mm) 1.00’’ (25,4 mm)
Controls:
controlled by two hand levers Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt driven dustproof 22 amp.
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand lever controlled, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt 70 amp.–hr. rating
Loader . . . . . . . . . . . . . . . . . . . . . Lift, tilt & auxiliary functions controlled DRIVE SYSTEM
by separate foot pedals. Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable sheave type
Engine . . . . . . . . . . . . . . . Handle lever throttle, key–type starter switch Clutches . . . . . . . . . . . . . . 4 (2 each side) single disc pressure lubricated
Primary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1 ratio
ENGINE Secondary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00:1 ratio
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Petter Final Drive . . . . . . . . . . . . . . #60H roller chain running in sealed oil bath
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BA2R Total Engine to Wheel Reduction . . . . . Variable from 37:1 to 100:1 ratio
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. 2 Diesel CAPACITIES
Governed Flywheel Horsepower . . . . . . . . . . 25 (25,4 kw) @ 3000 RPM Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 gal (41,6 L)
Maximum Torque . . . . . . . . . . . . . . . 43 ft.–lbs. (58,30 Nm) @ 2400 RPM Engine Lubricant Including Filter . . . . . . . . . . . . . . . . . . . . . 10.5 pt. (5,0 L)
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic Reservoir & Final Drive Case . . . . . . . . . . . . . . 17 gal. (64,4 L)
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . 3.500x3.625 in. (88,9x92,075 mm) Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 gal. (75,7 L)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 cubic inches (1,2L) TIRES
Cooling Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Standard . . . . 7:00x15–6 ply nylon steel cap w/Melroe special bar tread
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . Internal breathing Ballast (If Any) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 lbs. (140 kg)
Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3835 lbs. (1739,6 kg)
600, 600D, 610, 611 Loader

192 of78
Revised Dec. 214 –8C–4 Service Manual
MOTOR SPECIFICATIONS, (ELECTRIC)
Paragraph Page
Number Number
MOTOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D–1 8D–1
LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D–1
ELECTRIC
600, 600D, 610, 611 Loader

193 of Dec.
Added 214 78 –8D––1– Service Manual
600, 600D, 610, 611 Loader

194 of 214 –8D–0 Service Manual
600E LOADER (RELIANCE ELECTRIC)
135.5
(3442) 54
(1372)
120
(3048)
38° 108 65
17.5 (2743) (1651)
(445)
88 101
(2235) 31
(2565)
(787) 42
86
82 (1067)
(2184)
(2083)
45° 48
41 (1219)
(1041)
34
27°
8 (203) 87.5(191) 25° (864)
46
35 15 (1168)
79 (889) (381) 53.5
(2007) (1359)
107
PI–01459

(2718)
Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3550 (1610 kg) Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt driven, gear type
Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . . 1000 lbs. (453,6 kg) Minimum Pump Capacity . . . . . . . . . . . . 7.5 GPM (28 L/M) @ 1750 RPM
Tipping Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1840 lbs. (835 kg) Filtration . . . . . . . . . . . . Full flow on suction side with by–pass, condition
Raise to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 sec. Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doubleacting
Lower from Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 sec. Function Lift Tilt
Dumping Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.75 sec. Bore Diameter 2.00’’ (50,80 mm) 2.00’’ (50,8 mm)
Rollback Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.75 sec. Rod Diameter 1.25’’ (31.75 mm) 1.00’’ (25,4 mm)
Controls:
Vehicle . . . . . . . . . . . . . . . . . . . . . Forward, reverse & steering functions POWER TRAIN
controlled by two hand levers Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable sheave type
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand lever controlled, Clutches . . . . . . . . . . . . . . 4 (2 each side) single disc pressure lubricated
hydraulically adjusted variable sheave. Primary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00:1 ratio
Loader . . . . . . . . . . . . . . . . . . . . . Lift, tilt & auxiliary functions controlled Secondary Reductions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.00:1 ratio
by separate foot pedals. Final Drive . . . . . . . . . . . . . . #60H roller chain running in sealed oil bath
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pushbutton start & stop switch Total Engine to Wheel Reduction . . . . . Variable from 36:1 to 100:1 ratio
MOTOR (Motor Manufacturer’s Rating) CAPACITIES

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reliance Hydraulic Reservoir & Final Drive Case . . . . . . . . . . . . . . 17 gal. (64,4 L)
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TEFC–XP Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 gal. (75,7 L)
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . Explosion Proof Enclosure 254T
Rated Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . 15 (11 kw) continuous TIRES
Breakdown Torque . . . . . . . . . . . . . . . . . . . . . . . . . 440 volt: @ 1760 RPM Standard . . . . . . . . . . . . . . 7:00x15–6 ply nylon steel cap w/bar lug tread
380 volt: @ 1465 RPM
550 volt: @ 1760 RPM COUNTERWEIGHT
Operating Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 440 3 phrase–60 cycle Standard Cast Grill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 lbs. (45 kg)
380 3 phrase–50 cycle
550 3 phrase–60 cycle MACHINE WEIGHT (Less Attachment)
Motor Classification Rating . . . . . . . . . . . . . . . . . . . . . . Class 1–Group D; Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515 lbs. (1594 kg)
Class 2–Group E, F & G Shipping (Less Reel & Cable) . . . . . . . . . . . . . . . . . . . 2935 lbs. (1331 kg)
Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NEMA ’’A’’ Class ’’F’’
Cooling Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air
Cable Reel . . . . . . . . . . . . . . . . . . . Automatic retractable explosion proof
Cable & Size . . . . . . . . . . . . . . . . . . . . . . . . . 50 ft. (15,2 m) 10 gauge wire
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TECHNICAL DATA
Paragraph Page
Number Number
DECIMAL & MILLIMETER EQUIVALENTS . . . . . . . . . . . . . . . 8E–3
HYDRAULIC/HYDROSTATIC TRANSMISSION FLUID . . . . . 8E–2 8E–1
LOADER TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 8E–1 8E–1
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–3 8E–1
STANDARD TORQUE SPECIFICATIONS FOR BOLTS . . . . 8E–2
U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . 8E–3
TECHNICAL
DATA
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Added 214 78 –8E––1– Service Manual
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8E–1 LOADER TORQUE SPECIFICATIONS
The following special torques must be used on the Bobcat.
Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105–115 ft.–lbs. (102–119 Nm)
Hydraulic Fluid Filter Container Nut . . . . . . . . . . . . . . . . . . 12 ft.–lbs. (16,27 Nm)
Split Jackshaft Connector Screws . . . . . . . . . . . . . . . . . . 20 ft.–lbs. (27,116 Nm)
Clutch Sprocket Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ft.–lbs. (21,696 Nm)
Upper Jackshaft Locking Collar Set Screws . . . . . . . . . . 25 ft.–lbs. (33,895 Nm)
Gearcase Cover Mounting Nuts . . . . . . . . . . . . . . . . . . . . 30 ft.–lbs. (40,675 Nm)
Tapered Bore Drive Sheave to Crankshaft . . . . . . . . . . . 35 ft.–lbs. (47,454 Nm)
Lower Jackshaft (Large) Sprocket to Cluster Sprocket . . 55 ft.–lbs. (74,57 Nm)
Axle Hub Mounting Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 ft.–lbs. (88,128 Nm)
Upper Jackshaft Bearing Mounting Nuts . . . . . . . . . . . . . 70 ft.–lbs. (94,907 Nm)
Upright Brace Mounting Nuts . . . . . . . . . . . . . . . . . . . . . 80 ft.–lbs. (108,465 Nm)
1/2;; Inside Clutch Chain Tightener Nuts . . . . . . . . . . . . 85 ft.–lbs. (115,245 Nm)
9/16’’ Inside Clutch chain Tightener Nuts . . . . . . . . . . 110 ft.–lbs. (149,140 Nm)
Wheel Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . . 110 ft.–lbs. (149,140 Nm)
Lower Jackshaft Mounting Screws . . . . . . . . . . . . . . . . 110 ft.–lbs. (149,140 Nm)
Variable Speed Drive Sheave Retaining Nut . . . . . . . . 130 ft.–lbs. (172,256 Nm)
Upright Mounting Screws . . . . . . . . . . . . . . . . . . . . . . . . 150 ft.–lbs. (203,373 Nm)
Clutch Pin Holding Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 225 ft.–lbs. (305,059 Nm)
Axle Sprocket Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 ft.–lbs. (610 Nm)
8E–2 Hydraulic Fluid

The hydraulic system capacity is 20 gals. (75,7 L). The loader hydraulic system
reservoir must be filled only with fluid which will protect the components. For
operation in temperatures from below freezing up to hot climate conditions, use

10W–30 or 10W–40 engine oil which meets API Classification SE as replacement
fluid.
Where below zero temperatures are common, loaders must be kept in warm
building. Extra warm–up time must be used each time the loader is started during
very cold temperature conditions. Cold oil will not flow easily, and makes action
of the hydraulic components slower.
8E–3 Special Tools

The special tools for the loader can be ordered from the Tool Catalog (P/N
6556519).
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199 of February
Revised 214 80 –8E–1– Service Manual
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–Meter 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
600, 600D, 610, 611 Loader
Added Dec.200
78of 214 –8E–2 Service Manual
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
The following table shows standard torque specifications for bolts with zinc
phosphate coating. Bolts purchased from Clark that have zinc phosphate coating
are specified by the letter H following the part number.
THREAD SIZE SAE GRADE 5 SAE GRADE 8

INCH. 0.250 80–90 110–120
LBS. (9–10) (13–14)
(Nm)
0.3125 180–200 215–240
(21–23) (24–27)
0.375 25–28 35–40
(34–38) (48–54)
0.4375 40–45 60–65
(54–61) (82–88)
0.500 65–70 90–100
(88–95) (125–135)
0.5625 90–100 125–140
(125–135) (170–190)
0.625 125–140 175–190

(170–190) (240–260)
FOOT 0.750 220–245 300–330
LBS. (300–330) (410–450)
(Nm)
0.875 330–360 475–525
(450–490) (645–710)
1.000 475–525 725–800
(645–710) (985–1085)
1.125 650–720 1050–1175
(880–975) (1425–1600)
1.250 900–1000 1475–1625
(1200–1360) (2000–2200)
1.375 1200–1350 2000–2200
(1630–1830) (2720–2980)
1.500 1500–1650 2600–2850
(2040–2240) (3530–3870)
1.625 2000–2800 3450–3800
(2720–2980) (4680–5150)
1.750 2500–2750 4300–4800
(3390–3730) (5830–6500)
1.875 3150–3500 5500–6100
(4270–4750) (7450–8300)
2.000 3800–4200 6500–7200
(5150–5700) (8800–9800)
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GENERAL SERVICE
Paragraph Page
Number Number
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 9–1

ALPHABETICAL
INDEX
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204 of 214 –9–0 Service Manual
ALPHABETICAL INDEX
SUBJECT PAGE SUBJECT PAGE
Accessories, installation . . . . . . . . . . . . . . . . . . . . . . . 5–18 Driven Sheave (Straight Jackshaft), assembly . . . . 3–14
Accessories, removal . . . . . . . . . . . . . . . . . . . . . . . . . 5–11 Driven Sheave (Straight Jackshaft), disassembly . 3–14
Air Cleaner, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Driven Sheave (Tapered Jackshaft) . . . . . . . . . . . . . 3–13
Air Cleaner, heavy duty . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Air Cleaner, oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
Air Housing, installation . . . . . . . . . . . . . . . . . . . . . . . 5–18 Engine (Deutz), assembly . . . . . . . . . . . . . . . . . . . . . . 6–6
Engine (Deutz), general data . . . . . . . . . . . . . . . . . . . 6–31
Bolts and Studs, tightening . . . . . . . . . . . . . . . . . . . . . 6–1 Engine (Deutz), reconditioning . . . . . . . . . . . . . . . . . . 6–4
Brake, adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29 Engine (Petter), disassembly . . . . . . . . . . . . . . . . . . . . 7–1
Brake, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28 Engine (Petter), timing . . . . . . . . . . . . . . . . . . . . . . . . 7–10
Brake, disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28 Engine (Wisconsin), assembly after reconditioning 5–14
Engine (Wisconsin), reconditioning . . . . . . . . . . . . . 5–11
Camshaft (Petter), installation . . . . . . . . . . . . . . . . . . . 7–7 Engine (Wisconsin), removal . . . . . . . . . . . . . . . . . . . 5–11
Camshaft (Wisconsin), installation . . . . . . . . . . . . . . 5–14 Engine (Wisconsin), return to service . . . . . . . . . . . . 5–2
Camshaft (Petter), removal . . . . . . . . . . . . . . . . . . . . . 7–3 Engine (Wisconsin), storage . . . . . . . . . . . . . . . . . . . . 5–2
Camshaft (Wisconsin), removal . . . . . . . . . . . . . . . . 5–12 Engine Governor (Deutz), repair . . . . . . . . . . . . . . . . 6–20
Camshaft Gear (WIsconsin), installation . . . . . . . . . 5–17
Carburetor, adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 Flywheel (Wisconsin), installation . . . . . . . . . . . . . . . 5–18
Carburetor and Manifold, installation . . . . . . . . . . . . 5–18 Flywheel (Wisconsin), removal . . . . . . . . . . . . . . . . . 5–11
Carburetor and Manifold, removal . . . . . . . . . . . . . . 5–12 Frame Support Variable Speed, removal . . . . . . . . . 3–18
Carburetor Reconditioning . . . . . . . . . . . . . . . . . . . . . . 5–2 Front Cover (Deutz), check . . . . . . . . . . . . . . . . . . . . 6–20
Cartridge Release, adjustment . . . . . . . . . . . . . . . . . . 4–4 Fuel Adjustment (Petter) . . . . . . . . . . . . . . . . . . . . . . . 1–8
Cartridge Release, checking pressure setting . . . . . 4–4 Fuel Bowl (Wisconsin), disassemble . . . . . . . . . . . . . 5–3
Checks and Adjustment (Deutz) . . . . . . . . . . . . . . . . . 6–1 Fuel Bowl and

Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2 Intake Assembly (Wisconsin), assemble . . . . . . . . . 5–3
Clutch Needle Bearings, installing . . . . . . . . . . . . . . . 3–9 Fuel Bowl and Throttle Body (Wisconsin), assemble 5–4
Compression, check (Deutz) . . . . . . . . . . . . . . . . . . . . 6–2 Fuel Filter (Petter), assembly . . . . . . . . . . . . . . . . . . 7–10
Compression, return to normal (Deutz) . . . . . . . . . . . 5–1 Fuel Filter Lock–Off (Wisconsin), disassemble . . . . 5–10
Connecting Rod (Petter), assembly . . . . . . . . . . . . . . 7–8 Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7
Connecting Rod (Petter), removal . . . . . . . . . . . . . . . 7–2 Fuel Injection (Deutz), adjustment . . . . . . . . . . . . . . . 6–3
Connecting Rod Bearing (Deutz) . . . . . . . . . . . . . . . 6–24 Fuel Injection Nozzle (Deutz), removal–installation 6–30
Control Valve Seal, disassembly . . . . . . . . . . . . . . . . 4–10 Fuel Injection Pump (Deutz), check . . . . . . . . . . . . . . 6–2
Control Valve Seal, installation . . . . . . . . . . . . . . . . . . 4–8 Fuel Pump (Petter), installation . . . . . . . . . . . . . . . . . 7–10
Cooling Air blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–29 Fuel System (Deutz), check . . . . . . . . . . . . . . . . . . . . 6–2
Cooling System, engine . . . . . . . . . . . . . . . . . . . . . . . . 1–8
Crankcase Air Vent (Deutz) . . . . . . . . . . . . . . . . . . . . . 1–7 Gear Cover (Wisconsin), installation . . . . . . . . . . . . 5–17
Crankcase Air Vent (Wisconsin) . . . . . . . . . . . . . . . . . 1–7 Gear Cover (Wisconsin), removal . . . . . . . . . . . . . . . 5–12
Crankcase (Deutz), check . . . . . . . . . . . . . . . . . . . . . 6–17 Governor (Deutz), check and repair . . . . . . . . . . . . . 6–23
Crankshaft and Bearing (Deutz) . . . . . . . . . . . . . . . . 6–19 Governor (Petter), removal . . . . . . . . . . . . . . . . . . . . . 7–4
Crankshaft (Deutz), check . . . . . . . . . . . . . . . . . . . . . 6–17 Governor (Wisconsin), adjustment . . . . . . . . . . . . . . . 5–1
Crankshaft (Deutz), reconditioning . . . . . . . . . . . . . . 6–17
Crankshaft (Petter), removal . . . . . . . . . . . . . . . . . . . . 7–2 Hydraulic Circuit, operation . . . . . . . . . . . . . . . . . . . . . 4–1
Crankshaft (Wisconsin), installation . . . . . . . . . . . . . 5–15 Hydraulic Cylinder, assembly . . . . . . . . . . . . . . . . . . . 4–13
Crankshaft (Wisconsin), removal . . . . . . . . . . . . . . . 5–14 Hydraulic cylinder, disassembly . . . . . . . . . . . . . . . . 4–13
Cylinder (Deutz), check . . . . . . . . . . . . . . . . . . . . . . . 6–25 Hydraulic Fluid Filter, change . . . . . . . . . . . . . . . . . . . 1–3
Cylinder and Piston (Petter), installation . . . . . . . . . . 7–8 Hydraulic Oil, changing and adding . . . . . . . . . . . . . . 1–2
Cylinder Blocks (Wisconsin), installation . . . . . . . . . 5–15 Hydraulic Pump (500 electric), alignment . . . . . . . . 4–14
Cylinder Blocks (Wisconsin), removal . . . . . . . . . . . 5–14 Hydraulic Pump (600 Wisconsin), alignment . . . . . 4–15
Cylinder Head (Deutz), repair . . . . . . . . . . . . . . . . . . 6–26 Hydraulic Pump (Cessna), assembly . . . . . . . . . . . . 4–12
Cylinder Head (Petter), installation . . . . . . . . . . . . . . . 7–9 Hydraulic Pump (Webster), assembly . . . . . . . . . . . 4–11
Cylinder Head (Wisconsin), installation . . . . . . . . . . 5–17 Hydraulic Pump, checking condition . . . . . . . . . . . . . . 4–3
Cylinder Head (Wisconsin), removal . . . . . . . . . . . . 5–12 Hydraulic Pump (Cessna), disassembly . . . . . . . . . 4–12
Cylinder Seals, installation . . . . . . . . . . . . . . . . . . . . . 4–13 Hydraulic Pump Service (Webster) . . . . . . . . . . . . . . 4–10
Hydraulic System (600 electric, 600 Peter) . . . . . . . . 4–2
Decimal and Millimeter Equivalents . . . . . . . . . . . . . . 8–9 Hydraulic System
Decompressor Adjustment . . . . . . . . . . . . . . . . . . . . . 7–10 (600 & 610 Diesel w/Deutz Engine) . . . . . . . . . . . . . 4–1
Distributor (Wisconsin), maintenance . . . . . . . . . . . . 1–10 Hydraulic System (600 & 610 Gasoline & LP Gas) . 4–1
Drive Belt (Split Shaft), installation . . . . . . . . . . . . . . . 3–9 Hydraulic System, check pressure adjustment . . . . . 4–6
Drive Chain, adjustment . . . . . . . . . . . . . . . . . . . . . . . 3–26 Hydraulic System, checking condition of . . . . . . . . . . 4–2
Driven Sheave Alignment . . . . . . . . . . . . . . . . . . . . . . 3–14 Hydraulic Tanks, removing water . . . . . . . . . . . . . . . . 1–2
Driven Sheave, disassembly . . . . . . . . . . . . . . . . . . . 3–13
Driven Sheave, installation . . . . . . . . . . . . . . . . . . . . . 3–12 Idler Gear and Shaft (Wisconsin), installation . . . . . 5–17
Driven Sheave, removal . . . . . . . . . . . . . . . . . . . . . . . 3–11 Idler Gear and Shaft (Wisconsin), removal . . . . . . . 5–12
Ignition Timing (Wisconsin) . . . . . . . . . . . . . . . . . . . . . 1–9
Injector, installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11
600, 600D, 610, 611 Loader

Revised Dec. 78
ALPHABETICAL INDEX
SUBJECT PAGE SUBJECT PAGE
Jackshaft Bearing, installation . . . . . . . . . . . . . . . . . . 3–15 Valve Rocker (Petter), adjustment . . . . . . . . . . . . . . 7–10
Valve Rocker Gear (Petter), installation . . . . . . . . . . 7–10
Lower Jackshaft, installation . . . . . . . . . . . . . . . . . . . 3–24 Valve Spool Seals, installing in variable speed
Lower Jackshaft, removal . . . . . . . . . . . . . . . . . . . . . 3–23 control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9
Lower Jackshaft Sprocket, repair . . . . . . . . . . . . . . . 3–24 Valve and Seat Inserts, installation . . . . . . . . . . . . . . 5–15
LP Carburetor (Wisconsin), assembling . . . . . . . . . . 5–6 Valves and Seat Inserts (Wisconsin), removal . . . . 5–13
LP Carburetor (Wisconsin), cleaning & inspection . . 5–6 Valves Tappets (Wisconsin), removal . . . . . . . . . . . . 5–14
LP Carburetor (Wisconsin), disassembly . . . . . . . . . . 5–5 Vaporizer (Wisconsin), adjustment . . . . . . . . . . . . . . . 5–9
LP Carburetor (Wisconsin), reconditioning . . . . . . . . 5–5 Vaporizer (Wisconsin), assemble . . . . . . . . . . . . . . . . 5–8
LP Carburetor (Wisconsin), removal . . . . . . . . . . . . . 5–5 Vaporizer (Wisconsin), disassembling . . . . . . . . . . . . 5–8
LP Carburetor (Wisconsin), service . . . . . . . . . . . . . . 5–5 Vaporizer and Primary Regulator (Wisconsin),
LP Fuel Filter Lock–Off (Wisconsin) . . . . . . . . . . . . . 5–10 service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
Lubrication, loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 Variable Driven Sheave and Roto–Swivel
Inside, removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16
Main Bearing (Deutz), check–installation . . . . . . . . 6–18 Variable Sheave with Roto–Swivel Outside,
removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18
Oil, engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5 Variable Speed Control Valve, disassembly . . . . . . . 4–7
Oil Filter (Deutz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 Variable Speed Control Valve Seal Replacement . . . 4–7
Oil Filter (Petter) . . . . . . . . . . . . . . . . . . . . 1–6, 7–4, 7–10 Variable Speed Valve Pressure, checking . . . . . . . . . 4–5
Oil Filter (Wisconsin) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 Variable Speed W/Roto–Swivel Inside, assembly . 3–17
Oil Pan (Wisconsin), installation . . . . . . . . . . . . . . . . 5–16
Oil Pan (Wisconsin), removal . . . . . . . . . . . . . . . . . . 5–12 Water Scrubber Muffler (600 Diesel) . . . . . . . . . . . . . 1–8
Oil Pump (Deutz), checking . . . . . . . . . . . . . . . . . . . . 6–20
Oil Pump (Petter), lubricating . . . . . . . . . . . . . . . . . . . 7–6

Oil Pump (Petter), removal . . . . . . . . . . . . . . . . . . . . . 7–4
Oil Pump (Wisconsin), installation . . . . . . . . . . . . . . 5–16
Oil Pump (Wisconsin), removal . . . . . . . . . . . . . . . . . 5–12
Piston (Petter), assembly . . . . . . . . . . . . . . . . . . . . . . . 7–9

Piston (Deutz), check and measuring . . . . . . . . . . . 6–25
Piston and Connecting Rods (Wisconsin),
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16
Pistons and Connecting Rods (Wisconsin),
removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
Piston Pin Busing (Deutz check & replacement . . . 6–25
Piston Rings (Wisconsin), installation . . . . . . . . . . . 5–15
Rocker Arm, repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–29

Roto–Swivel, assembly . . . . . . . . . . . . . . . . . . . . . . . 3–17
Roto–Swivel, disassembly . . . . . . . . . . . . . . . . . . . . . 3–17
Service, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

Service, schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Spark Plug (Wisconsin) . . . . . . . . . . . . . . . . . . . . . . . 1–10
Specifications
600 (Gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–3
610 (Gasoline) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–4
600 (Deutz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–4
611 (Deutz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–5
611 (B of MA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–6
600 (Petter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–4
600E (Electric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D–1
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–12

Throttle Body, assemble . . . . . . . . . . . . . . . . . . . . . . . . 5–4
Throttle Body, disassemble . . . . . . . . . . . . . . . . . . . . . 5–2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10
Torque Specification for Bolts . . . . . . . . . . . . . . . . . . . 8–8
Torques, machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10
Troubleshooting the Drive System . . . . . . . . . . . . . . . 2–1
Troubleshooting the Engine . . . . . . . . . . . . . . . . . . . . 2–11
Troubleshooting the Hydraulic System . . . . . . . . . . . . 2–5
600, 600D, 610, 611 Loader

206 of 214 –9–2 Service Manual
019
® Bulletin Number
25 AUGUST 77
SERVICE BULLETIN Date
AFFECTING:
Product BOBCAT LOADER
Model 610, 620, 630, 700, 720
Manual No.
PROBLEM:
Too much fuel to engine.

CAUSE:
1. Fuel pump pressure is too high.
2. Float level needs adjustment.
CORRECTION:
1. Check fuel pump pressure by installing a ‘‘Tee’’ in the fuel line between
fuel pump and carburetor and connecting a gauge to the tee. Run engine at full
RPM. Correct pressure is 2–3 PSI. If pressure is too high, install new spring from
fuel pump repair kit, part number 6516387.
NOTE: Too low pressure will cause vapor lock.
2. Make adjustment of float level. The standard dimension as stated in the

Service Manuals is specified as 1–5/32’’ (Page 79, 610 S/M; Page 7–5, 700
S/M). It is sometimes helpful to change the float level adjustment to 1–1/4’’. This
is the recommendation for operation in areas of rough ground.
POLICY:
Melroe will give compensation for parts and one hour labor.
BULLETIN STATUS
No.(s) Printed in U.S.A. NON–CURRENT
207 of 214
208 of 214
042
® Bulletin Number
23 FEBRUARY 78
SERVICE BULLETIN Date
AFFECTING:
Product BOBCAT LOADER
Model 600, 600D, 610, 611
Manual No. 6556276

SUBJECT: SERVICE MANUAL REVISION
This Service Bulletin has 15 printed pages, count them to be sure you have all of them.

Remove Put In
Cover Page New Cover Page
Page 1–1 Page 1–1
Pages 1–9 & 1–10 Pages 1–9 thru 1–20
Page 5–1 Page 5–1
BULLETIN STATUS
No.(s) Printed in U.S.A. NON–CURRENT
209 of 214
210 of 214
600–002
® Revision Number
5 FEBRUARY 80
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 610 SALES MANAGER
Manual No. 6556276 (1–78)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
The following pages are a revision to the above Service Manual.

Take out existing pages and put in the new pages as listed below:

TAKE OUT PUT IN
1–1, 1–2 Revised 1–1, 1–2
1–3, 1–4 Revised 1–1, 1–4
1–5, 1–6 Revised 1–5, 1–6
Added 1–7a
1–7, 1–8 Revised 1–7, 1–8
3–1, 3–2 Revised 3–1, 3–2
Added 3–2a
Added 3–2b
3–3, 3–4 Revised 3–3, 3–4
3–5, 3–6 3–5, 3–6
3–7, 3–8 Revised 3–7, 3–8
4–1, 4–2 Revised 4–1, 4–2
4–3, 4–4 Revised 4–3, 4–4
4–15 Revised 4–15
Added 4–16
5–9, 5–10 Revised 5–9, 5–10
5–17, 5–18 Revised 5–17, 5–18
6–1, 6–2 Revised 6–1, 6–2
8A–1, 8A–2 Revised 8A–1, 8A–2
8A–3, 8A–4 Revised 8A–3, 8A–4
8B–1, 8B–2 Revised 8B–1, 8B–2
8B–3, 8B–4 Revised 8B–3, 8B–4
8B–5, 8B–6 Revised 8B–5, 8B–6
8C–1, 8C–2 Revised 8C–1, 8C–2
8E–1, 8E–2 Revised 8E–1, 8E–2
211 of 214
212 of 214
600–003
® Revision Number
22 APRIL 80
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 600, 610 SALES MANAGER
Manual No. 6556276 (1–78)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
The following pages are a revision to the above Service Manual.

Take out existing pages and put in the new pages as listed below:

TAKE OUT PUT IN
5–15, 5–16 Revised 5–15
Revised 5–16
Revised Feb. 8A–1 Revised Mar. 8A–1
Revised Feb. 8A–2 Revised Mar. 8A–2
213 of 214
214 of 214

Service Manual: Includes H Series

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6 6

Dealer Copy -- Not for Resale

6556276 (6–87) Printed in U.S.A. © Melroe Company 1987

CORRECT CORRECT CORRECT

B-10731a B-1537 B-7469

Dealer Copy -- Not for Resale

WRONG WRONG WRONG

B-6590 B-6580 B-6589

3. Lubricate the machine.

4. Check battery condition, electrolyte level and cables. HYDRAULIC

6. Check alternator drive belt for condition and tension.

Dealer Copy -- Not for Resale

8. Check tires for wear and pressure.

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

12. Operate the loader, checking all functions. PETTER ENGINE

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

600, 600D, 610, 611 Loader

600, 600D, 610, 611 Loader

Dealer Copy -- Not for Resale

600, 600D, 610, 611 Loader

600, 600D, 610, 611 Loader

Dealer Copy -- Not for Resale

600, 600D, 610, 611 Loader

1–2 LOADER LUBRICATION

Dealer Copy -- Not for Resale

1–3 CHANGING AND ADDING

1. Use tilt control to raise front

2. Allow the loader to stand for 3–4

3. Remove drain plug (Fig. 1–3) for

600, 600D, 610, 611 Loader

1–5 HYDRAULIC FLUID FILTER

1. Lower lift arms. Lift from of the

2. Remove floor panels and

Dealer Copy -- Not for Resale

5. Remove seal from center shaft

6. Clean parts in a cleaning fluid and

10. Lower the loader and run engine at

11. Check for leaks and check level of

600, 600D, 610, 611 Loader

1. See SERVICE SCHEDULE (Page

2. Clean all foreign material from

3. Remove old element (Fig. 1–7).

4. Install new element (Fig. 1–7).

5. Set indicator ring back to normal

6. Inspect air cleaner for leaks:

Dealer Copy -- Not for Resale

1–7 OIL TYPE AIR CLEANER

2. Remove bottom cup and clean.

2. When red ring is in window,

3. Inspect hoses and connection for Indicator

4. Inspect and clean vanes on air

600, 600D, 610, 611 Loader

2. Empty oil when engine is warmed up.

3. Capacity of oil for engine follows:

1–10 OIL SPECIFICATIONS FOR ENGINES

RECOMMENDED SAE VISCOSITY NUMBER

Dealer Copy -- Not for Resale

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE

600, 600D, 610, 611 Loader

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

3. Start engine and check for leaks.

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

5. Tighten filter by hand.