Bobcat 641, 642, 643 Loader 6566135 (6-12) (Preview)
MAINTENANCE SAFETY
SAFETY INSTRUCTIONS
– SAFETY IS YOUR RESPONSIBILITY
– BEFORE YOU WORK ON THE BOBCAT LOADER
CONTENTS
– FOREWORD
PREVENTIVE MAINTENANCE
– INTRODUCTION
— Serial Number Identification
— Loader Serial Number
— Engine Serial Number
– SERVICE SCHEDULE
– ENGINE SERVICE (General)
— Opening And Adjusting The Rear Door
— Engine Lubrication System
— Replacement Of Engine Oil And Filter
— Air Cleaner Service
– FUEL SYSTEM
— Fuel Filter (641)
— Fuel Filter (642)
— Fuel Filter (643)
— Removing Air From The Fuel System (641)
— Removing Air From The Fuel System (643)
– ENGINE COOLING SYSTEMS
— Removing Coolant From The Cooling System
– DRIVE BELTS
– ELECTRICAL SYSTEM SERVICE
— Using An Extra Battery
— Installing A New Battery
– HYDRAULIC/HYDROSTATIC SYSTEM
– HYDRAULIC/HYDROSTATIC OIL RESERVOIR
— Checking And Adding Oil
— Removing Hydraulic Oil
— Replacement Of The Hydraulic Filter
– FINAL DRIVE TRANSMISSION (CHAINCASE)
– TIRE MAINTENANCE
— Tire Rotation
– LUBRICATION OF THE BOBCAT LOADER
– OPERATOR GUARD
– BOB–TACH
– PIVOT PINS
– AUXILIARY CONTROL LOCKBOLT
– LIFT ARM STOP
– SPARK ARRESTOR MUFFLER
HYDRAULIC SYSTEM
– HYDRAULIC / HYDROSTATIC SCHEMATICS
– TROUBLESHOOTING
– HYDRAULIC SYSTEM INFORMATION
— 37° Flare Connections
— Straight Thread O–Ring Fitting
— Tubelines And Hoses
– HYDRAULIC CONTROL VALVE (Victor)
— Relief Valve
— Checking The Relief Valve
— Removal Of The Relief Valve
— Installation Of The Relief Valve
— Removal Of The Control Valve
— Disassembly Of The Control Valve (Victor)
— Assembly And Inspection Of The Control Valve
– HYDRAULIC CONTROL VALVE (Melroe)
— Relief Valve
— Installing A New Relief Valve
— Disassembling The Control Valve
— Inspecting The Control Valve
— Assembling The Control Valve
– HYDRAULIC PUMP
— Checking Output Of The Hydraulic Pump
— Removing The Hydraulic Pump
— Checking The Hydraulic Pump
— Removing And Checking The Pump Shaft
— Installing The Hydraulic Pump
— Starting Procedure For The Hydraulic Pump
– LIFT CYLINDERS
— Checking The Lift Cylinders
— Removing The Lift Cylinder
— Disassembly Of The Cylinder
— Assembly Of The Lift Cylinder
— Installation Of The Lift Cylinder(s)
– TILT CYLINDER
— Checking The Tilt Cylinder
— Removing The Tilt Cylinder
— Disassembly Of The Tilt Cylinder
— Installation Of The Tilt Cylinder
– HYDRAULIC/HYDROSTATIC RESERVOIR
— Removing The Hydraulic/Hydrostatic Reservoir
— Installing The Hydraulic/Hydrostatic Reservoir
– OIL COOLER
— Removing The Oil Cooler On The 641
— Removing The Oil Cooler From The 642 & 643
— Installing The Oil Cooler
– 10 MICRON FILTER BY–PASS VALVE
— Removing By–Pass Valve
— Installation Of The By–Pass Valve
– CONTROL PEDAL, LINKAGE AND LOCKS
— Removing Hydraulic Control Pedal
— Installing The Hydraulic Control Pedal
— Adjusting The Hydraulic Control Pedal
— Pedal Lock Linkage
HYDROSTATIC SYSTEM
– TROUBLESHOOTING
– HYDROSTATIC SYSTEM INFORMATION
— Function Of High Pressure Relief Replenishing Valves
– STEERING LEVERS
— Removing The Steering Levers
— Repairing The Steering Levers
— Installing The Steering Levers
– STEERING LINKAGE
— Adjustment Of The Steering Linkage
— Removing The Steering Linkage
— Repairing The Pintle Lever
— Installing The Steering Linkage
– PORT BLOCK
— 40 Micron Filter
— Cold Weather By–Pass Valve
— Neutral By–Pass Valve
— Removing The Port Block
— Installing The Port Block
– HYDROSTATIC MOTOR
— Removing The Hydrostatic Motor (Model 109–1174–006 & Above)
— Removing The Hydrostatic Motor (Model 109–1052–006 & Below)
— Disassembly Of The Hydrostatic Motor
— Hydrostatic Motor Inspection
— Assembly Of The Hydrostatic Motor
— Installing The Hydrostatic Motor (Model 109–1173–006 & Above) (Splined Shaft)
— Installing the Hydrostatic Motor (Model 109–1052–006 & Below)
— Start–Up Procedure For The Hydrostatic Motor
– HYDROSTATIC PUMP
— Checking The High Pressure Relief Replenishing Valves
— Removing The Hydrostatic Pumps
— Disassembly Of The Hydrostatic Pump
— Hydrostatic Pump Inspection
— Assembly Of The Hydrostatic Pump
— Installing Pumps To Manifold Block
— Installing Hydrostatic Pump Assembly
– TOWING THE BOBCAT LOADER
DRIVE SYSTEM
– BRAKES
— Brake Adjustment
— Brake Removal
– FINAL DRIVE
— Chain Replacement
– AXLES AND BEARINGS
— Axle And Bearing Removal
— Assembly Of The Axles
— Installing The Axles
– CHAINCASE FLUID
— Replacing The Chaincase Fluid
MAIN FRAME
– RAISING AND LOWERING THE OPERATOR GUARD
— Raising The Operator Guard
— Lowering The Operator Guard
— Jumper Start Switch
– OPERATOR GUARD REMOVAL AND INSTALLATION
— Removing The Operator Guard
— Operator Guard Installation
– BOB–TACH FRAME (40 Series)
— Removing The Bob–Tach
— Disassembly Of The Bob–Tach
— Assembly Of The Bob–Tach
— Installing The Bob–Tach
– LIFT ARMS
— Removing The Lift Arms
— Installing The Lift Arms
– REAR DOOR
— Removing The Rear Door
— Installing The Rear Door
— Adjusting The Rear Door Latch
– FUEL TANK
— Removing The Fuel Tank
— Installing The Fuel Tank
– BOB–TACH (50 Series)
— Removal And Installation
— Bob–Tach Lever And Wedge
ELECTRICAL SYSTEM
– ELECTRICAL SCHEMATICS
– TROUBLESHOOTING
– ELECTRICAL SYSTEM INFORMATION
— Electrical Circuitry
— Safety Procedures For The Battery
— Alternator Damage
– BATTERIES
— Checking The Battery
– WIRE HARNESS FOR THE OPERATOR GUARD
— Removing The Wire Harness For The Operator Guard
— Installing The Wire Harness For The Operator Guard
– WIRE HARNESS FOR THE ENGINE
— Removing The Wire Harness For The Engine
— Installing The Wire Harness For The Engine
– ALTERNATOR
— Checking The Alternator
— Removing The Alternator
— Repairing The Alternator
— Installing The Alternator
– STARTER
— Checking The Starter
— Removing The Starter
— Repairing The Starter
ENGINE SERVICE
– ENGINE SERVICE (641 DEUTZ)
— TROUBLESHOOTING
— FUEL SYSTEM
— Fuel System Service
— Venting Air From The Fuel System
— Fuel Filters
— Fuel Water Trap
— Fuel Lift Pump
— Fuel Injection Pump
— Removal Of The Injection Pump
— Injection Pump Service
— Installing The Injection Pump
— Checking Adjustment Of Fuel Delivery
— FUEL INJECTION NOZZLES
— Removal
— Disassembly And Repair Of Injector (In The Shop)
— Installation Of The Injector
— BLOWER FAN
— Removal Of The Blower Fan
— Disassembly Of The Blower Fan
— Assembly Of The Blower Fan
— Installation Of The Blower Fan
— ENGINE SERVICE
— ENGINE REMOVAL
— CYLINDER HEAD AND VALVES
— Removal And Disassembly
— Repair And Assembly
— Checking Piston Crown Clearance And Installation Of Cylinder Head
— CYLINDER, PISTONS AND CONNECTING RODS
— Assembly
— OIL PUMP, FILTER HOUSING AND RELIEF VALVE
— Oil Pump Removal
— Installation
— Oil Pressure Relief Valve
— ENGINE FRONT COVER
— Removal
— Disassembly And Inspection
— Assembly
— Installation
— GOVERNOR
— Removal And Disassembly
— Assembly And Installation
— CAMSHAFT
— Removal
— Installation
— Crankshaft Removal
— Inspection
— Assembly
— UNIVERSAL JOINT
— Universal Joint Removal
— Universal Joint Installation
— FLYWHEEL
— Flywheel Removal
— Flywheel Installation
— Removing The Ring Gear
— ENGINE OIL COOLER
— ENGINE SHROUDING
— ENGINE MOUNTS
— Replacing Engine Mounts
— MUFFLER
— Removal Of The Muffler
— STARTER
— Starter Removal
– ENGINE SERVICE (642 FORD)
— TROUBLESHOOTING
— CHECKS AND ADJUSTMENTS
— Oil Pressure
— Valve Clearance
— Compression
— Carburetor, Throttle And Governor Adjustments
— Ignition System
—- Spark Plug Wires Resistance Test
—- Spark Plug Test
—- Distributor Tests
—- Dwell Angle Check
—- Spark Strength Tests
—- Battery To Coil Voltmeter Test
—- Starting Ignition Circuit Voltmeter Test
—- Breaker Point Gap Adjustment
— Ignition Timing
— CARBURETOR REPAIR
— ENGINE DIAGNOSIS AND TESTING
— Camshaft Lobe Lift
— Crankshaft End Play
— Flywheel Surface Alignment Check
— Camshaft End Play
— ENGINE REMOVAL
— ENGINE REPAIR
— Valve Guides
— Grinding The Valve Seats
— Valves
— Grinding Valves
— Select Fitting Of The Valves
— Camshaft Repair
— Crankshaft
— Repairing Journals
— To Check Crankshaft Or Connection Rod Bearings With Plastigage
— Installing Pistons
— Installing Piston Rings
— Installing The Piston Pins
— Valve Rocker Arm And Shaft Assembly
— Push Rods
— CYLINDER BLOCK
— Finishing The Cylinder Walls
— CYLINDER HEADS
— Cleaning The Cylinder Heads
— Checking The Cylinder Heads
— TAPPETS
— Cleaning The Tappets
— Checking The Tappets
— CAMSHAFT
— Cleaning And Checking The Camshaft
— CRANKSHAFT
— Checking The Crankshaft
— FLYWHEEL
— Checking The Flywheel
— CONNECTING RODS
— Cleaning The Connecting Rods
— Checking The Connecting Rods
— PISTONS, PINS AND RINGS
— Cleaning The Pistons, Pins and Rings
— Checking The Pistons, Pins And Rings
— MAIN BEARING AND CONNECTING ROD BEARINGS
— Cleaning Bearings
— Checking Bearings
— CYLINDER BLOCK
— Cleaning The Cylinder Block
— Checking The Cylinder
— OIL PUMP
— Cleaning The Oil Pump
— Checking The Oil Pump
— VALVE ROCKER ARM COVER AND ROCKER ARM SHAFT
— Removing And Disassembly Of The Rocker Arm Shaft
— Installing Rocker Arm Shaft
— VALVE PUSHRODS
— Removing The Valve Pushrods
— Installing The Valve Pushrods
— INTAKE MANIFOLD
— Removing The Intake Manifold
— Installing The Intake Manifold
— CYLINDER HEAD
— Removing The Cylinder Head
— Installing The Cylinder Head
— VALVE SPRING, RETAINER AND STEM SEAL (With The Cylinder Head Removed)
— Removing The Valve Spring
— Installing The Valve Spring
— VALVE SPRING, RETAINER AND STEM SEAL (With The Cylinder Head Installed)
— Installing The Valve Spring
— WATER PUMP
— Removing The Water Pump
— CYLINDER FRONT COVER, TIMING CHAIN AND CRANKSHAFT SPROCKETS
— Removal
— Removing The Timing Cover
— Installation Of The Timing Cover
— FRONT OIL SEAL
— Removing The Front Oil Seal
— FRONT OIL SEAL
— Removing The Oil Seal
— Installing The Oil Seal
— TIMING CHAIN TIGHTENING
— Removing The Chain Tightener
— Installing The Chain Tightener
— CAMSHAFT AND VALVE LIFTERS
— Removing The Camshaft And Valve Lifters
— Installing The Camshaft And Valve Lifters
— OIL PAN
— Removing The Oil Pan
— Installing The Oil Pan
— OIL PUMP
— Removing The Oil Pump
— Installing The Oil Pump
— CRANKSHAFT REAR OIL SEAL
— Removing The Rear Oil Seal
— Installing The Rear Oil Seal
— MAIN BEARINGS
— Removing The Main Bearings
— Installing The Main Bearings
— CONNECTING ROD BEARINGS
— Removing The Connecting Rod Bearings
— Installing The Connecting Rod Bearings
— PISTONS AND CONNECTING RODS
— Removing The Pistons And Connecting Rods
— Installing The Pistons And Connecting Rods
— CAMSHAFT BEARINGS
— Removing The Camshaft
— CRANKSHAFT
— Installing The Crankshaft
— UNIVERSAL JOINT
— Universal Joint Installation
— FLYWHEEL
— Flywheel Removal
— FLYWHEEL RING GEAR
— Removing The Ring Gear
— Installing The Ring Gear
— MUFFLER
— Removing The Muffler
— RADIATOR
— Removing The Radiator
— Installing The Radiator
— BLOWER HOUSING
— Removing The Blower Housing
— Installing The Blower Housing
— STARTER
— Removing The Starter
— Installing The Starter
– ENGINE SERVICE (643 KUBOTA)
— TROUBLESHOOTING
— FUEL SYSTEM
— Replacing The Fuel Filter
— To Remove The Air From The Fuel System
— Checking Glow Plugs
— Removal And Installation Of The Fuel Injection Pump
— Timing The Fuel System
— Fuel Injector Nozzles
— REMOVING AND INSTALLING THE ENGINE
— Removing The Engine
— Installing The Engine
— REPAIRING THE CYLINDER HEAD
— Removing The Cylinder Head
— Disassembly Of The Cylinder Head
— Servicing The Cylinder Head
— Assembly Of The Cylinder Head
— Installing The Cylinder Head
— Adjusting The Compression Release Mechanism (S/N 11620 and Below Only)
— REPAIRING THE ENGINE
— Removing The Gear Case
— Removing The Timing Gear, Camshaft And Oil Pump
— Removing Pistons And Crankshaft
— Servicing The Timing Gear And Camshaft
— Servicing The Connecting Rods And Pistons
— Servicing The Crankshaft
— Servicing The Cylinder Liners
— Servicing The Oil Pump
— Servicing The Water Pump
— ASSEMBLY OF THE ENGINE
— Installing The Crankshaft
— Installing Pistons
— Installing The Camshaft And Timing Gears
— Installing The Gear Case Cover
— UNIVERSAL JOINT
— Removing The U–Joint
— Installing The U–Joint
— FLYWHEEL
— Removing The Flywheel
— Installing The Flywheel
— MUFFLER
— Removing The Muffler
— RADIATOR
— Removing The Radiator
— Installing The Radiator
— BLOWER HOUSING
— Removing The Blower Housing
— Installing The Blower Housing
— STARTER
— Removing The Starter
— Installing The Starter
TECHNICAL DATA
– TECHNICAL DATA (641 DEUTZ)
— 641 LOADER SPECIFICATIONS
— OPERATION & PERFORMANCE SPECIFICATIONS
— ENGINE SPECIFICATIONS
— HYDRAULIC SYSTEM
— HYDRAULIC CYLINDERS
— HYDROSTATIC TRANSMISSION & FINAL DRIVE
— ELECTRICAL
— TIRES
— FLUID CAPACITIES
— ENGINE SPECIFICATIONS, 641 (Deutz – F2L511)
— Fuel System
— Governor, Front Cover And Throttle
— Cylinder Head And Valves
— Cylinder, Piston And Connecting Rod
— Camshaft, Crankshaft, Bearings
— Lubrication System
— Torque Specifications (Deutz Engine)
– TECHNICAL DATA (642 FORD)
— 642 LOADER SPECIFICATIONS
— OPERATION & PERFORMANCE
— ENGINE SPECIFICATIONS
— HYDRAULIC SYSTEM
— HYDRAULIC CYLINDERS
— HYDROSTATIC TRANSMISSION & FINAL DRIVE
— ELECTRICAL
— TIRES
— FLUID CAPACITIES
— ENGINE SPECIFICATIONS, 642 (Ford)
— Fuel Specifications
— Engine Oil
— Lubrication System
— Cylinder Heads
— Valve Mechanism
— Camshaft
— Crankshaft
— Connecting Rod
— Piston
— Piston Pin
— Piston Rings
— Cylinder Block
— Ignition system
— Starter
— Torque Specifications For Engine
– TECHNICAL DATA (643 KUBOTA)
— 643 LOADER SPECIFICATIONS
— OPERATION & PERFORMANCE
— ENGINE SPECIFICATIONS
— HYDRAULIC SYSTEM
— HYDROSTATIC TRANSMISSION & FINAL DRIVE
— ELECTRICAL
— TIRES
— FLUID CAPACITIES
— ENGINE SPECIFICATIONS
— Fuel Injection Nozzles
— Fuel Injection Pump
— Cylinder Head
— Valves
— Valve Springs
— Rocker Arms
— Camshaft
— Cylinder
— Piston Rings
— Pistons
— Crankshaft
— Oil Pump
— Engine Oil
— ENGINE BOLT TORQUES
– TECHNICAL DATA
— TORQUE SPECIFICATIONS
— Engine Group (641)
— Engine Group (642)
— Engine Group (643)
— Mainframe Group (All 640 Series)
— Seat Bar, Fuel Tank & Panel Group
— Steering Levers, Linkage Pedal Group (640 Series)
— Brake, Axle And Chaincase Group (640 Series)
— Hydraulic/Hydrostatic Group (640 Series)
— HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
— Hydraulic/Hydrostatic Fluid
— DECIMAL AND MILLIMETER EQUIVALENTS
— U.S. TO METRIC CONVERSION
— STANDARD TORQUE SPECIFICATIONS FOR BOLTS
SERVICE BULLETINS
– 640-001
– 640-002
SERVICE MANUAL REVISIONS
– 640-3
– 640-4
– 640–5
– 640–6
– 640–7
– 640–8
– 640–9
– 640–10
– 640–11
– 640–12
– 640–13
– 640–14
– 640–15
– 640–16
– 640–17
– 640–18
– 640–19
– 640–20
– 640-21
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