TROUBLESHOOTING THE ENGINE................. 2
Contents
1. on F PR Control lever pivots Clutch shafts fasteners 7 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 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 Hydraulic cylinder leaks internal 600 600D 610 611 Loader 26 Service Manual 2 2 TROUBLESHOOTING THE HYDRAULIC SYSTEM Cont d PROBLEM ll OOAUSE OO O CORRECTION 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 le2. 600D 610 611 Loader 2 2 Service Manual 2 1 TROUBLESHOOTING THE DRIVE SYSTEM Cont d PROBLEM ou conmecrov Lubricant fitting on variable speed Spring hits the fitting under Turn spring so it will clear fitting compression driven sheave is breaking off Belt hits bottom on drive sheave Move lever forward to move belt outward when placing variable speed in low position Loss of power with drive beit 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 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 alignment to be off wear Bore of fixed half of driven sheave is Install sheave and jackshaft worn Too high lift pressure Correct pressure Sprocket holding nuts are loose Tighten and lock the nuts Breaking of drive belt Chains are tight and there is free play in wheels Worn axle splines or multiple Install new axle or sprockets sprockets Using wrong sprockets Install correct sprockets Using wrong type chain Install correct c
3. G THE ENGINE Cont d CORRECTION improper carburetor idling Make carburetor adjustment adjustment Carburetor jets dil Spark plug gap is small Make adjustment of gap gaskets Weak coil or condenser Imsainew Wompiston rings mme 000 Fuel mixture Make adjustment of carburetor or choke Choke not open Inspect linkage and setting PROBLEM Engine will not stop 5 5 1 5 Oil consumption Light blue exhaust smoke 5 6 7 Black exhaust smoke Excessive fuel used Spark plugs dirty Dirty air cleaner Service the air cleaner Crankcase pressure Clean vent valve Bad indicator Install new indicator 1 1 1 5 6 7 Low oil pressure Oil is light Empty Fill with correct oil Add ol Incorrect oil pressure setting Make adjustment 5 6 7 Leaking fuel pump Install new fuel pump Install new indicator 56 7 High oil pressure 56 7 Badly worn oil pump 5 6 7 Empty fil with correct oil Clean all lines and openings 5 6 7 Oil relief valve stuck Clean by pass Install when 5 6 7 needed O Jo lo 2 e 9 la a 9 Aa o lt I o 3 600 600D 610 611 Loader 2 15 Service Manual 600 600D 610 611 Loader Service Manual
4. NE ENGINE TYPE D Diesel A All G Gas CORRECTION Sectio Bad fuse in the wiring Install new fuse 5 6 7 L oose battery connection Clean battery terminals and 5 6 7 connect cables tightening them Battery is discharged Charge battery Check charging 5 6 7 system PROBLEM Engine will not turn over Bad starter switch Install new switch 5 6 7 Loose starter connections Tighten connections 5 6 7 Broken or disconnected wiring Connect or repair wiring hamess 5 6 7 harness The variable speedis in high speed Pull variable speed drive control lever all the way back before stopping engine Engine fails to start or is difficult to start Make adjustment of clutches so levers will travel 3 to 4 inches from neutral position in each direction The clutches are engaged with steering levers in neutral position The loader will move while starting Refer to Starting Procedure in Bobcat Operation section of this manual Starting procedure is not correct No fuel in tank Put in fuel 5 6 7 The engine air cleaner is dirty 5 6 7 The air vent hole in fuel tank cap is Remove and clean cap plugged Fuel ine leaks 56 7 Damaged fuel pump Repair or install new pump 5 6 7 The carburetor is not being choked Choke as required enough The carburetor is being choked too Correct choking procedures 5 much when starting a warm engine Water dirt o
5. TROUBLESHOOTING Paragraph Page Number Number TROUBLESHOOTING THE DRIVE SYSTEM 2 1 2 1 TROUBLESHOOTING THE ENGINE ee 2 3 2 11 ES TROUBLESHOOTING THE HYDRAULIC SYSTEM 2 2 2 5 SHOOTING 600 600D 610 611 Loader Service Manual Y 600 600D 610 611 Loader Service Manual 2 1 TROUBLESHOOTING THE DRIVE SYSTEM rom ousse CORRECTION Clutch will not drive or engage Make clutch adjustment eae Putin correct oil 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 overtightened 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 A oO Rough races on clutch plates Install new bearings and races on Early clutch thrust bearings failure both clutches Operator putting more force than Use less force on levers necessary on levers Wrong amount of counterweight Use correct counterweight Alignment nut not making correct Free alignment nut alignment Rough clutch faces Install clutch face and lining Clutch adjustment not correct Install clutch lining and make clutch adjustment Early clutch lining failu
6. aks install O ring Add new oil Remove the cylinder and weld Add new oil Smooth rod and install seal There is a hole in the valve housing Make adjustment of linkage so the spool is centered in the valve housing with the control pedal in neutral position The valve spool is marked Install new valve The valve body is marked Install new valve The load check valve will not seat Clean and install any parts correctly needed Running the variable speed at af Do not run continuously at one constant high variable speed position variable speed position holding pressure buildup in the cylinder can cause seal failure Hydraulic control valve leaks external The control linkage is out of adjustment Hydraulic control valve leaks internal Lift arm does not drift down but drops when raised slowly Put shims behind the cast sprin holding bracket Install 020 thic shims on fastening bolts Make adjustment for release pressure of 600 PSI Worn O rings in the plunger Install new O rings There is a high holding pressure Let the loader cool buildup in the variable speed cylinder Loosen the hydraulic hose fitting at the check valve to release some of the pressure The plunger in the holding release valve part of the control valve is too long It will not allow the check ball to seat The variable speed cylinder will not hold in high
7. buretor flooding Check carburetor adjustment EN Governor out of adjustment Correct adjustment Sticking valves Free the valves Fuel screen fuel of foreign material Clean 5 Pitted valves Grind or install new Dirty engine may be dueto blocked Clean and clear 5 6 7 exhaust Wrong fuel Drain the fuel system and fill with 5 6 7 clean correct fuel Dirty Air cleaner Service the air cleaner 6 7 Incorrect fuel timing Make adjustment amp 7 Broken compression ring Check Install new 6 7 5 6 7 Excessive carbon on pistons and Cleanthe carbon from the cylinder cylinder head head and pistons Worn cylinder and pistons Recondition the engine 587 600 600D 610 611 Loader 2 13 Service Manual 2 3 TROUBLESHOOTING THE ENGINE Cont d Engine is overloaded Operate at a lower variable speed Ref Section See Owner s Manual PROBLEM Engine overheats Operate at a 3 4 to full throttle setting Engine cooling fins are dirty Clean the cooling fins ngine has been operated with part Clean the cooling fins and install of the housing removed housing Blower not operating Check drive 9 N o 2 D D Ej 2 a o gt gt a 2 3 D o o 0 e o a a w a m J a lt o Q o 2 lt Q gt a a 9 E Dirty engine oil using wrong grade of engine oil je tc The crankcase oil level is low il Excessi
8. e pedal in neutral position Check for a bad spool or rough 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 There is a hole in the filter element Install new filter element 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 Ibs 1 7 m kgf The condition indicator gauge is bad Install new gauge o Fr o ul o ul wu o 600 600D 610 611 Loader 2 8 Service Manual 2 2 TROUBLESHOOTING THE HYDRAULIC SYSTEM Cont d PROBLEM CAUSE CORRECTION 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 t
9. eseat the valves 5 6 7 Valve tappets out of adjustment Make adjustment 5 6 7 Cylinders dry due to engine having f Correct compression by pouringa 5 6 7 been out of use for some time Smal amount of engine oil into cylinders Loose spark plugs Install new gaskets and tighten Damaged cylinder head gasket or Install new gasket and tighten 5 loose cylinder head Piston rings stuck in piston Clean the parts and install new 5 rings 5 compression Air in the fuel system Bleed the system Fuel filter is plugged Install a new element 5 6 7 Faulty injector nozzle Check clean and make 6 7 adjustment Faulty injector pump Make adjustment or install new pump Wrong decompressor setting Make adjustment Air in fuel lines Bleed the system Water in the fuel system ty fuel system Fill with clean uel 600 600D 610 611 Loader 2 12 Service Manual 6 7 6 7 6 7 6 7 Engine runs rough Power is low Engine may stop 6 7 6 7 5 6 7 o e N 2 3 TROUBLESHOOTING THE ENGINE Cont d Air in fuel system Check for and correct leaks Bad injector nozzle Check clean and make 6 adjustment PROBLEM Engine runs rough Power is low Engine may stop 7 Lo 7 5 6 7 7 Bad breaker points gaskets 7 Engine fails to start or is difficult to start Loose ignition cables or worn or Repair or tighten or install new broken cables Car
10. filter condition indicator on the right dash panel are tight Air in hydraulic oil Air is leaking into the suction side of pump 600 600D 610 611 Loader 2 9 Service Manual 2 2 TROUBLESHOOTING THE HYDRAULIC SYSTEM Cont d PROBLEM CAUSE CORRECTION Air in hydraulic oil Cont d Air is leaking into the cushion side of Inspect to be sure all connections at the hydraulic oil filter are tight pump Cont d 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 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 not hold in overthe center position control linkage Master release valve setting is low Make adjustment master release valve Master release valve is dirty Hydraulic pump worn Install new pump Cartridge release un in left and Make correct adjustment auxiliary control valve is low 600 600D 610 611 Loader 2 10 Service Manual Hydraulic pressure gauge indicates less than 1650 116 kgf cm2 with pressure control valve open 3 2 3 TROUBLESHOOTING THE ENGI
11. hain Breaking of axle sprocket 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 Fig pyese 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 Breaking of axle 600 600D 610 611 Loader 2 3 Service Manual 2 1 TROUBLESHOOTING THE DRIVE SYSTEM Cont d on same side of loader Using more counterweight than is Use correct amount of needed counterweight 600 600D 610 611 Loader 2 4 Service Manual Y 2 2 TROUBLESHOOTING THE HYDRAULIC SYSTEM PROBLEM cause commecron Hydraulic system failure Cil 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 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 Rough hydraulic movemen
12. hrust 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 Oil supply is low hydraulic oil Fill the reservoir to the upper check opening Noise in hydraulic pump 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 mepes for and correct any air reservoir and pump leaks Worn pump coupling Install new coupling Oil supply is low hydraulic oil Fill the reservoir to the upper check opening The oil is dirty Empty the reservoir and fill with clean oil The master release valve setting is Check the pressure and set to proper release setting 1700 25 psi 119 5 1 8 kgf cm low Lift amp auxiliary relief valve set low Set to 1800 100 psi 126 5 Wrong grade oil Empty the reservoir and change to Wrenagmdesl correct weight oil The hydraulic oil is heating Hydraulic pump seal leaks There is internal wear Install new parts The oil supply is low Fill the reservoir to the upper check openings Inspect all fittings and fasteners and tighten Inspect to be sure the fittings on back of the vacuum gauge hydraulic oil
13. ing 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 5 Service Manual 2 2 TROUBLESHOOTING THE HYDRAULIC SYSTEM Cont d PROBLEM cause conmecroN Lift arms drift with bucket empty Dirty check valve at the left control Clean check valve valve section Lift control linkage is out off 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 because of wrong fastening Fasten valve group with only the three outside bolts putting shims under the valve on the bolts to fasten it away from plate Check all bolts and nuts for looseness Make repairs when there is leakage beyond seals or gaskets Fill oil in reservoir to make up for lost oil Loose of hydraulic fluid in hydraulic Oil may be leaking beyond any of system external these seals or gaskets 1 Clutch shaft caps Gearcase side panels Axle Upper jackshaft Check all seals and replace any allowing oil loss Lower jackshaft fastenings
14. ough inside Smooth and install seal kit Clutch thrust bearing Install new bearing Threads are bad on actuator nut Install new actuator nut Splines are wom on direction control Install new lever and shaft lever or linkage shaft Bolt is missing from direction control lever Splines are wom on direction control Tighten the bolt lever or linkage shaft Increase in direction control lever movement in one direction Direction control lever side play Holding nut is worn Install new nut Direction control lever linkage is loose Tighten the bolt on lever Spring washers are not in place on 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 Loud noise in drive system Primary chain is over tightened Loosen and make adjustment Chain is out of alignment Make correct alignment Upper jackshaft bearings are bad Install new bearings Secondary chain is out of adjustment Make correct adjustments Lower jackshaft sprocket is loose Tighten sprocket Self alignment nut is not turned 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 Side panel is difficult to install 600
15. r foreign materialin fuel Drain and clean fuel system Fill 5 6 7 with clean fuel Dirty carburetor Clean carburetor The ignition cable is disconnected Connect ignition cable from magneto distributor or spark plugs Broken ignition cables cause short Repair or install new cables circuits a m e o o 9o D N E N 3 ai o N 600 600D 610 611 Loader 2 11 Service Manual 2 3 TROUBLESHOOTING THE ENGINE Cont d Ref The ignition cables distributor or Dry and clean them 5 spark plugs are wet PROBLEM Engine fail to start or is difficult to start Cont d a Moisture in ignition system due to Store idle loader in a dry place as 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 and wash it off frequently with diesel fuel Spray ignition system with a sealant made to prevent moisture problems i The spark plugs are wet or dirty Clean or instali new spark plugs the spark plug gaps are wrong Gap or install new Engine fails to start or is difficult to start Bad condenser or coll Instan new 0000 The ignition is out ot ime Bad distributor Repair or install new 1 5 6 7 Wrong crankcase oil cold weather Use an engine oil of proper viscosity The valves are leaking or sticking Clean and r
16. re and wear 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 Upper jackshaft sprocket not in Make adjustment for correct alignment with outer clutch sprocket alignment Chain is over tightened Make chain adjustment More than normal primary drive chain wear Bearing in backward Install bearing correctly Bad shaft Inspect shaft and install new shaft Bad seal in bearing Install new bearing and seal Oil leakage of upper jackshaft bearings Bad gasket for bearing housing Tighten housing holding bolts O ring seal installed wrong Bad O r ng seal Install new gasket Tighten cap Oil leakage by clutch shaft caps Install new O ring seal 600 600D 610 611 Loader 2 1 Service Manuai 2 1 TROUBLESHOOTING THE DRIVE SYSTEM Cont d PROBLEM CORRECTION 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 rive Install new O rings Stationary half sheave r
17. speed position on models equipped with variable speed control valve with holding pressure release No change when the variable speed control lever is put in low A position on loaders with a check valve Replace the variable speed control valve with one having a pressure release valve 600 600D 610 611 Loader 2 7 Service Manual 2 2 TROUBLESHOOTING THE HYDRAULIC SYSTEM Cont d Tilt control valve body split The bucket will not hold tilted back with the control in neutral position The lift arms drift down from raised position with the lift control pedal in neutra position The hydraulic oil filter condition indicator shows no reading at full engine RPM 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 E The release valve pressure is too high Lower the release settirig to 1800 in lift and auxiliary valve to 1900 PSI Oil leaks between the valve spool and Spool is worn or seals are bad the valve housing with the spool centered There is an external oil leak between Check for external leaks and the lift control valve and cylinders correct 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 th
18. t Check all fittings and fasteners for tightness Check that fittings on back of the vacuum gauge hydraulic oil filter condition indicator on right instrument panel are tight A leak between reservoir and hydraulic pump causes airto enter the pump Foreign material in clutch manifold Remove the valve and clean it release valve holds valve open so air is pulled into the hydraulic pump through the clutch shafts Change the hydraulic oil filter whenever the indicator needle on the gauge is in red zone The large nut on end of filter container Tighten ge 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 Lifting more than loaders rated Operate loader within rated 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 When spool is not centered in the valve with the pedal in neutral position make linkage adjustment Dirty hydraulic oil filter is causing low flow and high vacuum Lift arm raises slowly at full engine RPM Leaking spool inside lift cylinder When spool or valve housing is broken or marked replace the valve Hydraulic pump is worn and not Check condition of the pump and deliver
19. ve valve clearance j 5 6 7 Restriction in exhaust Remove restriction 5 6 7 Oo Faulty injector nozzles j r 6 7 Faulty injector pump Make adjustment or install new 6 7 Install new pistons 56 7 Worn connecting rod bearings Instali new bearings 5 6 7 Loose flywheel i i i 6 7 damaged Worn main bearings i ings 5 6 7 proper lubrication bearings Carbon on the pistons Clean the carbon from top of pistons 5 6 7 and from cylinder heads Fuel timing is wring Make adjustment of timing Broken piston ring Install a new ring or rings Engine is not being lubricated Check operation of engine oil pump properly Engine making hitting noise D N 5 6 7 9 sg z o o w 5 33 2 0 Ly x 9 53 D 3 n w 2 o lg2 a O mu Oo un 9 128 z en 2 3 3 3 0 S o w Q 2 5 2 5 D a gt gt 3 o 3 gt 3 w o E y Lo M 3 0 a 3 Q 3 7 T a c 9 O Q 3 3 zc o o O 2 9 O LA o x a a Poor grade of gasoline Use good grade gasoline Always operate at 3 4 to full throttle at low speed setting Add oil Change o Making timing adjustment Install correct spark plug W Excessive camshaft end clearance 600 600D 610 611 Loader 2 14 Service Manual 5 6 7 Oo io ol gt gt 0 gt gt gt gt gt gt gt gt gt gt gt lo g m e Oo ha jos 1 ja N Make adjustment 5 6 7 2 3 TROUBLESHOOTIN
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