Bobcat 641, 642, 643 Skid-Steer Loader Repair Service Manual - 6566135

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This workshop repair service manual PDF download for the 641, 642, 643 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Loader 641 
Bobcat Loader 642 
Bobcat Loader 643 


TABLE OF CONTENTS :

PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE
TECHNICAL DATA
ALPHABETICAL INDEX
SERVICE BULLETINS
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6566135 (10–86)
Total Pages : 384


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

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MAINTENANCE SAFETY
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
    
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