Bobcat 641 642 643 Loader Service Manual 6566135 (6-12) – PDF DOWNLOAD

Description

Bobcat 641 642 643 Loader Service Manual 6566135 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 641 642 643 Loader Service Manual 6566135 (6-12) – PDF DOWNLOAD

Language : English
Pages : 386
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 641 642 643 Loader Service Manual 6566135 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
SAFETY INSTRUCTIONS 5
SAFETY IS YOUR RESPONSIBILITY 5
BEFORE YOU WORK ON THE BOBCAT LOADER 5
CONTENTS 7
FOREWORD 7
PREVENTIVE MAINTENANCE 9
INTRODUCTION 11
Serial Number Identification 11
Loader Serial Number 11
Engine Serial Number 11
SERVICE SCHEDULE 13
ENGINE SERVICE (General) 14
Opening And Adjusting The Rear Door 14
Engine Lubrication System 14
Replacement Of Engine Oil And Filter 15
Air Cleaner Service 17
FUEL SYSTEM 18
Fuel Filter (641) 18
Fuel Filter (642) 19
Fuel Filter (643) 19
Removing Air From The Fuel System (641) 19
Removing Air From The Fuel System (643) 20
ENGINE COOLING SYSTEMS 20
Removing Coolant From The Cooling System 21
DRIVE BELTS 22
ELECTRICAL SYSTEM SERVICE 23
Using An Extra Battery 23
Installing A New Battery 24
HYDRAULIC/HYDROSTATIC SYSTEM 25
HYDRAULIC/HYDROSTATIC OIL RESERVOIR 25
Checking And Adding Oil 25
Removing Hydraulic Oil 26
Replacement Of The Hydraulic Filter 27
FINAL DRIVE TRANSMISSION (CHAINCASE) 27
TIRE MAINTENANCE 27
Tire Rotation 28
LUBRICATION OF THE BOBCAT LOADER 28
OPERATOR GUARD 29
BOB–TACH 29
PIVOT PINS 30
AUXILIARY CONTROL LOCKBOLT 30
LIFT ARM STOP 30
SPARK ARRESTOR MUFFLER 31
HYDRAULIC SYSTEM 33
HYDRAULIC / HYDROSTATIC SCHEMATICS 35
TROUBLESHOOTING 59
HYDRAULIC SYSTEM INFORMATION 60
37° Flare Connections 60
Straight Thread O–Ring Fitting 60
Tubelines And Hoses 60
HYDRAULIC CONTROL VALVE (Victor) 61
Relief Valve 61
Checking The Relief Valve 61
Removal Of The Relief Valve 62
Installation Of The Relief Valve 62
Removal Of The Control Valve 62
Disassembly Of The Control Valve (Victor) 63
Assembly And Inspection Of The Control Valve 65
HYDRAULIC CONTROL VALVE (Melroe) 66
Relief Valve 66
Installing A New Relief Valve 66
Disassembling The Control Valve 66
Inspecting The Control Valve 69
Assembling The Control Valve 69
HYDRAULIC PUMP 72
Checking Output Of The Hydraulic Pump 72
Removing The Hydraulic Pump 72
Checking The Hydraulic Pump 75
Removing And Checking The Pump Shaft 75
Installing The Hydraulic Pump 75
Starting Procedure For The Hydraulic Pump 76
LIFT CYLINDERS 76
Checking The Lift Cylinders 76
Removing The Lift Cylinder 77
Disassembly Of The Cylinder 78
Assembly Of The Lift Cylinder 79
Installation Of The Lift Cylinder(s) 81
TILT CYLINDER 82
Checking The Tilt Cylinder 82
Removing The Tilt Cylinder 82
Disassembly Of The Tilt Cylinder 83
Installation Of The Tilt Cylinder 84
HYDRAULIC/HYDROSTATIC RESERVOIR 84
Removing The Hydraulic/Hydrostatic Reservoir 84
Installing The Hydraulic/Hydrostatic Reservoir 84
OIL COOLER 85
Removing The Oil Cooler On The 641 85
Removing The Oil Cooler From The 642 & 643 85
Installing The Oil Cooler 85
10 MICRON FILTER BY–PASS VALVE 86
Removing By–Pass Valve 86
Installation Of The By–Pass Valve 86
CONTROL PEDAL, LINKAGE AND LOCKS 86
Removing Hydraulic Control Pedal 86
Installing The Hydraulic Control Pedal 87
Adjusting The Hydraulic Control Pedal 87
Pedal Lock Linkage 88
HYDROSTATIC SYSTEM 89
TROUBLESHOOTING 91
HYDROSTATIC SYSTEM INFORMATION 92
Function Of High Pressure Relief Replenishing Valves 92
STEERING LEVERS 93
Removing The Steering Levers 93
Repairing The Steering Levers 94
Installing The Steering Levers 94
STEERING LINKAGE 95
Adjustment Of The Steering Linkage 95
Removing The Steering Linkage 97
Repairing The Pintle Lever 97
Installing The Steering Linkage 98
PORT BLOCK 98
40 Micron Filter 98
Cold Weather By–Pass Valve 99
Neutral By–Pass Valve 100
Removing The Port Block 101
Installing The Port Block 101
HYDROSTATIC MOTOR 102
Removing The Hydrostatic Motor (Model 109–1174–006 & Above) 102
Removing The Hydrostatic Motor (Model 109–1052–006 & Below) 102
Disassembly Of The Hydrostatic Motor 103
Hydrostatic Motor Inspection 108
Assembly Of The Hydrostatic Motor 109
Installing The Hydrostatic Motor (Model 109–1173–006 & Above) (Splined Shaft) 114
Installing the Hydrostatic Motor (Model 109–1052–006 & Below) 114
Start–Up Procedure For The Hydrostatic Motor 115
HYDROSTATIC PUMP 115
Checking The High Pressure Relief Replenishing Valves 115
Removing The Hydrostatic Pumps 117
Disassembly Of The Hydrostatic Pump 119
Hydrostatic Pump Inspection 122
Assembly Of The Hydrostatic Pump 124
Installing Pumps To Manifold Block 130
Installing Hydrostatic Pump Assembly 132
TOWING THE BOBCAT LOADER 132
DRIVE SYSTEM 133
BRAKES 135
Brake Adjustment 135
Brake Removal 136
FINAL DRIVE 138
Chain Replacement 138
AXLES AND BEARINGS 139
Axle And Bearing Removal 139
Assembly Of The Axles 141
Installing The Axles 141
CHAINCASE FLUID 142
Replacing The Chaincase Fluid 142
MAIN FRAME 143
RAISING AND LOWERING THE OPERATOR GUARD 145
Raising The Operator Guard 145
Lowering The Operator Guard 145
Jumper Start Switch 146
OPERATOR GUARD REMOVAL AND INSTALLATION 146
Removing The Operator Guard 146
Operator Guard Installation 147
BOB–TACH FRAME (40 Series) 147
Removing The Bob–Tach 147
Disassembly Of The Bob–Tach 148
Assembly Of The Bob–Tach 149
Installing The Bob–Tach 151
LIFT ARMS 152
Removing The Lift Arms 152
Installing The Lift Arms 153
REAR DOOR 154
Removing The Rear Door 154
Installing The Rear Door 154
Adjusting The Rear Door Latch 154
FUEL TANK 155
Removing The Fuel Tank 155
Installing The Fuel Tank 155
BOB–TACH (50 Series) 156
Removal And Installation 156
Bob–Tach Lever And Wedge 159
ELECTRICAL SYSTEM 161
ELECTRICAL SCHEMATICS 164
TROUBLESHOOTING 187
ELECTRICAL SYSTEM INFORMATION 188
Electrical Circuitry 188
Safety Procedures For The Battery 188
Alternator Damage 189
BATTERIES 189
Checking The Battery 189
WIRE HARNESS FOR THE OPERATOR GUARD 189
Removing The Wire Harness For The Operator Guard 189
Installing The Wire Harness For The Operator Guard 190
WIRE HARNESS FOR THE ENGINE 191
Removing The Wire Harness For The Engine 191
Installing The Wire Harness For The Engine 191
ALTERNATOR 191
Checking The Alternator 191
Removing The Alternator 192
Repairing The Alternator 193
Installing The Alternator 195
STARTER 195
Checking The Starter 195
Removing The Starter 196
Repairing The Starter 196
ENGINE SERVICE 199
ENGINE SERVICE (641 DEUTZ) 201
TROUBLESHOOTING 203
FUEL SYSTEM 204
Fuel System Service 204
Venting Air From The Fuel System 204
Fuel Filters 205
Fuel Water Trap 205
Fuel Lift Pump 206
Fuel Injection Pump 206
Removal Of The Injection Pump 206
Injection Pump Service 206
Installing The Injection Pump 206
Checking Adjustment Of Fuel Delivery 208
FUEL INJECTION NOZZLES 209
Removal 209
Disassembly And Repair Of Injector (In The Shop) 209
Installation Of The Injector 209
BLOWER FAN 210
Removal Of The Blower Fan 210
Disassembly Of The Blower Fan 210
Assembly Of The Blower Fan 210
Installation Of The Blower Fan 211
ENGINE SERVICE 211
ENGINE REMOVAL 211
CYLINDER HEAD AND VALVES 214
Removal And Disassembly 214
Repair And Assembly 214
Checking Piston Crown Clearance And Installation Of Cylinder Head 216
CYLINDER, PISTONS AND CONNECTING RODS 217
Assembly 218
OIL PUMP, FILTER HOUSING AND RELIEF VALVE 219
Oil Pump Removal 219
Installation 219
Oil Pressure Relief Valve 219
ENGINE FRONT COVER 219
Removal 219
Disassembly And Inspection 220
Assembly 220
Installation 221
GOVERNOR 222
Removal And Disassembly 222
Assembly And Installation 222
CAMSHAFT 223
Removal 223
Installation 223
Crankshaft Removal 223
Inspection 224
Assembly 224
UNIVERSAL JOINT 225
Universal Joint Removal 225
Universal Joint Installation 225
FLYWHEEL 225
Flywheel Removal 225
Flywheel Installation 225
Removing The Ring Gear 226
ENGINE OIL COOLER 226
ENGINE SHROUDING 226
ENGINE MOUNTS 226
Replacing Engine Mounts 226
MUFFLER 227
Removal Of The Muffler 227
STARTER 227
Starter Removal 227
ENGINE SERVICE (642 FORD) 229
TROUBLESHOOTING 231
CHECKS AND ADJUSTMENTS 232
Oil Pressure 232
Valve Clearance 232
Compression 232
Carburetor, Throttle And Governor Adjustments 233
Ignition System 235
Spark Plug Wires Resistance Test 235
Spark Plug Test 235
Distributor Tests 235
Dwell Angle Check 236
Spark Strength Tests 236
Battery To Coil Voltmeter Test 236
Starting Ignition Circuit Voltmeter Test 237
Breaker Point Gap Adjustment 237
Ignition Timing 237
CARBURETOR REPAIR 238
ENGINE DIAGNOSIS AND TESTING 238
Camshaft Lobe Lift 238
Crankshaft End Play 239
Flywheel Surface Alignment Check 239
Camshaft End Play 240
ENGINE REMOVAL 240
ENGINE REPAIR 242
Valve Guides 242
Grinding The Valve Seats 242
Valves 243
Grinding Valves 243
Select Fitting Of The Valves 243
Camshaft Repair 243
Crankshaft 243
Repairing Journals 243
To Check Crankshaft Or Connection Rod Bearings With Plastigage 243
Installing Pistons 244
Installing Piston Rings 245
Installing The Piston Pins 245
Valve Rocker Arm And Shaft Assembly 245
Push Rods 245
CYLINDER BLOCK 245
Finishing The Cylinder Walls 245
CYLINDER HEADS 246
Cleaning The Cylinder Heads 246
Checking The Cylinder Heads 246
TAPPETS 246
Cleaning The Tappets 246
Checking The Tappets 247
CAMSHAFT 247
Cleaning And Checking The Camshaft 247
CRANKSHAFT 247
Checking The Crankshaft 247
FLYWHEEL 247
Checking The Flywheel 247
CONNECTING RODS 247
Cleaning The Connecting Rods 247
Checking The Connecting Rods 247
PISTONS, PINS AND RINGS 248
Cleaning The Pistons, Pins and Rings 248
Checking The Pistons, Pins And Rings 248
MAIN BEARING AND CONNECTING ROD BEARINGS 248
Cleaning Bearings 248
Checking Bearings 248
CYLINDER BLOCK 248
Cleaning The Cylinder Block 248
Checking The Cylinder 249
OIL PUMP 249
Cleaning The Oil Pump 249
Checking The Oil Pump 249
VALVE ROCKER ARM COVER AND ROCKER ARM SHAFT 250
Removing And Disassembly Of The Rocker Arm Shaft 250
Installing Rocker Arm Shaft 250
VALVE PUSHRODS 251
Removing The Valve Pushrods 251
Installing The Valve Pushrods 251
INTAKE MANIFOLD 251
Removing The Intake Manifold 251
Installing The Intake Manifold 251
CYLINDER HEAD 252
Removing The Cylinder Head 252
Installing The Cylinder Head 252
VALVE SPRING, RETAINER AND STEM SEAL (With The Cylinder Head Removed) 253
Removing The Valve Spring 253
Installing The Valve Spring 253
VALVE SPRING, RETAINER AND STEM SEAL (With The Cylinder Head Installed) 253
Installing The Valve Spring 254
WATER PUMP 255
Removing The Water Pump 255
CYLINDER FRONT COVER, TIMING CHAIN AND CRANKSHAFT SPROCKETS 255
Removal 255
Removing The Timing Cover 255
Installation Of The Timing Cover 256
FRONT OIL SEAL 256
Removing The Front Oil Seal 256
FRONT OIL SEAL 257
Removing The Oil Seal 257
Installing The Oil Seal 257
TIMING CHAIN TIGHTENING 257
Removing The Chain Tightener 257
Installing The Chain Tightener 257
CAMSHAFT AND VALVE LIFTERS 257
Removing The Camshaft And Valve Lifters 257
Installing The Camshaft And Valve Lifters 258
OIL PAN 259
Removing The Oil Pan 259
Installing The Oil Pan 260
OIL PUMP 260
Removing The Oil Pump 260
Installing The Oil Pump 260
CRANKSHAFT REAR OIL SEAL 260
Removing The Rear Oil Seal 260
Installing The Rear Oil Seal 261
MAIN BEARINGS 261
Removing The Main Bearings 261
Installing The Main Bearings 261
CONNECTING ROD BEARINGS 262
Removing The Connecting Rod Bearings 262
Installing The Connecting Rod Bearings 262
PISTONS AND CONNECTING RODS 262
Removing The Pistons And Connecting Rods 262
Installing The Pistons And Connecting Rods 263
CAMSHAFT BEARINGS 263
Removing The Camshaft 263
CRANKSHAFT 264
Installing The Crankshaft 264
UNIVERSAL JOINT 265
Universal Joint Installation 265
FLYWHEEL 265
Flywheel Removal 265
FLYWHEEL RING GEAR 266
Removing The Ring Gear 266
Installing The Ring Gear 266
MUFFLER 266
Removing The Muffler 266
RADIATOR 266
Removing The Radiator 266
Installing The Radiator 268
BLOWER HOUSING 268
Removing The Blower Housing 268
Installing The Blower Housing 269
STARTER 269
Removing The Starter 269
Installing The Starter 269
ENGINE SERVICE (643 KUBOTA) 271
TROUBLESHOOTING 273
FUEL SYSTEM 274
Replacing The Fuel Filter 274
To Remove The Air From The Fuel System 274
Checking Glow Plugs 274
Removal And Installation Of The Fuel Injection Pump 275
Timing The Fuel System 276
Fuel Injector Nozzles 276
REMOVING AND INSTALLING THE ENGINE 277
Removing The Engine 277
Installing The Engine 279
REPAIRING THE CYLINDER HEAD 280
Removing The Cylinder Head 280
Disassembly Of The Cylinder Head 281
Servicing The Cylinder Head 281
Assembly Of The Cylinder Head 283
Installing The Cylinder Head 283
Adjusting The Compression Release Mechanism (S/N 11620 and Below Only) 284
REPAIRING THE ENGINE 285
Removing The Gear Case 285
Removing The Timing Gear, Camshaft And Oil Pump 286
Removing Pistons And Crankshaft 287
Servicing The Timing Gear And Camshaft 288
Servicing The Connecting Rods And Pistons 289
Servicing The Crankshaft 290
Servicing The Cylinder Liners 291
Servicing The Oil Pump 292
Servicing The Water Pump 293
ASSEMBLY OF THE ENGINE 293
Installing The Crankshaft 293
Installing Pistons 294
Installing The Camshaft And Timing Gears 294
Installing The Gear Case Cover 295
UNIVERSAL JOINT 296
Removing The U–Joint 296
Installing The U–Joint 296
FLYWHEEL 296
Removing The Flywheel 296
Installing The Flywheel 296
MUFFLER 296
Removing The Muffler 296
RADIATOR 297
Removing The Radiator 297
Installing The Radiator 298
BLOWER HOUSING 299
Removing The Blower Housing 299
Installing The Blower Housing 299
STARTER 300
Removing The Starter 300
Installing The Starter 300
TECHNICAL DATA 301
TECHNICAL DATA (641 DEUTZ) 303
641 LOADER SPECIFICATIONS 305
OPERATION & PERFORMANCE SPECIFICATIONS 305
ENGINE SPECIFICATIONS 305
HYDRAULIC SYSTEM 306
HYDRAULIC CYLINDERS 306
HYDROSTATIC TRANSMISSION & FINAL DRIVE 306
ELECTRICAL 306
TIRES 306
FLUID CAPACITIES 306
ENGINE SPECIFICATIONS, 641 (Deutz – F2L511) 307
Fuel System 307
Governor, Front Cover And Throttle 307
Cylinder Head And Valves 307
Cylinder, Piston And Connecting Rod 307
Camshaft, Crankshaft, Bearings 308
Lubrication System 308
Torque Specifications (Deutz Engine) 309
TECHNICAL DATA (642 FORD) 311
642 LOADER SPECIFICATIONS 313
OPERATION & PERFORMANCE 313
ENGINE SPECIFICATIONS 313
HYDRAULIC SYSTEM 313
HYDRAULIC CYLINDERS 314
HYDROSTATIC TRANSMISSION & FINAL DRIVE 314
ELECTRICAL 314
TIRES 314
FLUID CAPACITIES 314
ENGINE SPECIFICATIONS, 642 (Ford) 315
Fuel Specifications 315
Engine Oil 315
Lubrication System 316
Cylinder Heads 316
Valve Mechanism 316
Camshaft 317
Crankshaft 317
Connecting Rod 317
Piston 317
Piston Pin 317
Piston Rings 318
Cylinder Block 318
Ignition system 318
Starter 318
Torque Specifications For Engine 319
TECHNICAL DATA (643 KUBOTA) 321
643 LOADER SPECIFICATIONS 323
OPERATION & PERFORMANCE 323
ENGINE SPECIFICATIONS 323
HYDRAULIC SYSTEM 323
HYDROSTATIC TRANSMISSION & FINAL DRIVE 324
ELECTRICAL 324
TIRES 324
FLUID CAPACITIES 324
ENGINE SPECIFICATIONS 325
Fuel Injection Nozzles 325
Fuel Injection Pump 325
Cylinder Head 325
Valves 325
Valve Springs 325
Rocker Arms 325
Camshaft 325
Cylinder 326
Piston Rings 326
Pistons 326
Crankshaft 326
Oil Pump 326
Engine Oil 326
ENGINE BOLT TORQUES 327
TECHNICAL DATA 329
TORQUE SPECIFICATIONS 331
Engine Group (641) 331
Engine Group (642) 332
Engine Group (643) 334
Mainframe Group (All 640 Series) 336
Seat Bar, Fuel Tank & Panel Group 337
Steering Levers, Linkage Pedal Group (640 Series) 338
Brake, Axle And Chaincase Group (640 Series) 339
Hydraulic/Hydrostatic Group (640 Series) 340
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 341
Hydraulic/Hydrostatic Fluid 341
DECIMAL AND MILLIMETER EQUIVALENTS 342
U S TO METRIC CONVERSION 342
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 343
SERVICE BULLETINS 345
640-001 345
640-002 347
SERVICE MANUAL REVISIONS 345
640-3 349
640-4 351
640–5 353
640–6 355
640–7 357
640–8 359
640–9 361
640–10 363
640–11 365
640–12 367
640–13 369
640–14 371
640–15 373
640–16 375
640–17 377
640–18 379
640–19 381
640–20 383
640-21 385

DESCRIPTION:

Bobcat 641 642 643 Loader Service Manual 6566135 (6-12) – PDF DOWNLOAD

SAFETY IS YOUR RESPONSIBILITY:

We care about your safety.
The Bobcat loader is designed to give maximum operator safety; but no machine design can prevent operator error or
carelessness.
BEFORE YOU WORK ON THE BOBCAT LOADER:

• This SERVICE MANUAL was written to give the serviceman (mechanic) instructions
  for safe adjustments and/or repairs of the Bobcat loader.
• Read the complete sequence in the paragraph (Example: 4–3.1 Axle and Bearing
  Removal Steps 1 thru 14) so you know the complete removal procedure before the
  work is actually started.
• Always use jackstands and lift arm stops so you have a safe working area around the
  Bobcat loader.

FORWARD:
This Service Manual gives the instructions for correct servicing, adjustment and overhauling of
the Bobcat loader Hydraulic/Hydrostatic System, Drive System, Main Frame, Electrical System
and Engine Service.
Make reference to the Operator’s Manual for operating instructions (Starting, Daily Checks,
Loader Operation, etc.).
A general inspection of the following items must be made when the Bobcat loader has had
service or repair.
1. Check hydraulic/hydrostatic fluid level, engine oil level and fuel supply.
2. Inspect for any sign of fuel, oil or hydraulic fluid leaks.
3. Lubricate the loader.
4. Check the condition of the battery(ies) and the cables.
5. Inspect the air cleaner system for damage or leaks.
6. Check the warning lights to see if they light.
7. Check tires for wear and pressure.
8. Check the Bob–Tach for wear and see if the wedges are damaged.
9. Check the safety items for condition (Operator Guard, Seat Belt, Seat Bar, Safety Signs
(Decals), Safety Treads, etc.).
10. Make an inspection for loose or broken parts or connections.
11. Operate the loader, checking all functions.

IMAGES PREVIEW OF THE MANUAL:

Need help? Contact: [email protected]

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.V