Bobcat 642B Loader Service Manual 6570275 (6-12) – PDF DOWNLOAD

Description

Bobcat 642B Loader Service Manual 6570275 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 642B Loader Service Manual 6570275 (6-12) – PDF DOWNLOAD

Language : English
Pages : 230
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 642B Loader Service Manual 6570275 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
SAFETY INSTRUCTIONS 9
SERIAL NUMBER LOCATIONS 10
LOADER SERIAL NUMBER 10
ENGINE SERIAL NUMBER 10
DELIVERY REPORT 10
BOBCAT LOADER IDENTIFICATION 11
PREVENTIVE MAINTENANCE 13
SERVICE SCHEDULE 15
LIFTING AND BLOCKING THE BOBCAT LOADER 16
Procedure 16
TRANSPORTING THE BOBCAT LOADER 17
Procedure 17
LIFT ARM STOP 18
Procedure 18
OPERATORS CAB 19
Raising the Operator Cab 19
Lowering the Operator Cab 20
SEAT BAR SYSTEM 21
USING EXTRA BATTERY (JUMP START) 22
Procedure 22
Seat Bar Description 21
Seat Bar Inspection 21
Seat Bar Maintenance 21
REMOTE START SWITCH 23
Procedure 23
HYDRAULIC SYSTEM 25
HYDRAULIC / HYDROSTATIC SCHEMATICS 27
TROUBLESHOOTING 41
HYDRAULIC SYSTEM INFORMATION 42
Flare Connections 42
Straight Thread O–ring Fitting 42
Tubelines and Hoses 42
LIFT CYLINDER 43
Checking the Lift Cylinder(s) 43
Removal and Installation 43
TILT CYLINDER 45
Checking the Tilt Cylinder 45
Removal and Installation 45
Rod End Seal 46
HYDRAULIC CONTROL VALVE 47
Checking the Main Relief Valve with Auxiliary Couplers (Opt ) 47
Checking The Main Relief Valve W/O Auxiliaries 48
Main Relief Valve Removal And Installation 49
Adjusting The Main Relief Valve 49
Removal And Installation 50
HYDRAULIC PUMP 52
Checking The Output Of The Hydraulic Pump 52
Removal And Installation 53
PORT BLOCK 55
Removal And Installation 55
Cold Weather By–Pass Valve 56
Case Drain Relief Valve 57
HYDRAULIC FLUID FILTER HOUSING 58
Removal and Installation 58
Sender Switch 59
HYDRAULIC FLUID RESERVOIR 60
Removal And Installation 60
HYDRAULIC CONTROL PEDALS 61
Removal And Installation 61
Adjustment 61
PEDAL LOCK LINKAGE 62
Adjustment 62
HYDROSTATIC SYSTEM 63
TROUBLESHOOTING 65
Chart 65
HYDROSTATIC SYSTEM INFORMATION 66
High Pressure Relief/Replenishing Valve Function 66
FRONT PANEL 67
Removal And Installation 67
STEERING LEVERS 69
Removal And Installation 69
Repairing The Steering Levers 70
STEERING LINKAGE 71
Steering Linkage Adjustment 71
Removal And Installation 72
Repairing The Pintle Lever 73
HYDROSTATIC MOTOR 74
Removal And Installation 74
HYDROSTATIC PUMP 76
Checking Charge Pressure 76
Charge Pressure Relief Valve 76
Checking High Pressure Relief Valves 77
Removal And Installation 78
High Pressure Hose Routing 80
Tow Valves 80
DRIVE SYSTEM 81
PARKING BRAKE 83
Adjustment 83
Removal and Installation 83
Block and Pucks 84
AXLES, SEALS AND BEARINGS 86
Removal 86
Installation 87
FINAL DRIVE CHAIN 90
Removal 90
Installation 90
CHAINCASE FLUID 91
Replacing the Chaincase Fluid 91
MAIN FRAME 93
OPERATOR CAB 95
Removal And Installation 95
OPERATOR CAB GAS CYLINDER 98
Removal And Installation 98
REAR DOOR 99
Door Latch Adjustment 99
Removal And Installation 100
LIFT ARMS 101
Removal And Installation 101
BOB–TACH FRAME (40 Series) 103
Removal and Installation 103
Tilt Cylinder Rod End Seal 104
Disassembly and Assembly 105
BOB–TACH (50 Series) 107
Removal And Installation 107
Bob–Tach Lever And Wedge 110
FUEL TANK 112
Removal And Installation 112
ELECTRICAL SYSTEM 113
ELECTRICAL SCHEMATICS 116
ELECTRICAL SYSTEM 125
Description 125
TROUBLESHOOTING 125
Chart 125
BATTERY 126
Checking The Battery 126
Removal And Installation 126
ALTERNATOR 127
Checking The Alternator Output 127
Checking the Alternator Regulator 127
Removal and Installation 128
Disassembly And Assembly 129
STARTER 132
Checking The Starter 132
Removal And Installation 132
Disassembly And Assembly 133
Cleaning and Inspection 134
Replacing the Brushes 134
ENGINE SERVICE 135
TROUBLESHOOTING 137
Chart 137
VALVE CLEARANCE 138
Adjustment 138
ENGINE COMPRESSION 139
Checking 139
IGNITION TIMING 140
Procedure 140
DISTRIBUTOR 141
Removal And Installation 141
Point Gap Adjustment 141
Disassembly And Assembly 142
Checking Centrifugal Advance 142
Checking Vacuum Advance 142
CARBURETOR 143
Description 143
Removal And Installation 146
Disassembly And Assembly 147
Inspection 147
Adjustment 147
Governor Adjustment 148
Governor Oil Level 148
FUEL PUMP 149
Removal And Installation 149
Inspection 149
Check The Fuel Pump 149
Fuel Filter 149
ENGINE BELT SHIELD 150
Removal And Installation 150
REAR GRILL 151
Removal and Installation 151
ENGINE 152
Removal And Installation 152
OIL COOLER AND BLOWER HOUSING 156
Removal And Installation 156
RADIATOR 159
Removal And Installation 159
ENGINE MUFFLER 160
Removal And Installation 160
ENGINE FLYWHEEL AND U–JOINT 161
Removal And Installation 161
Flywheel Ring Gear 161
ROCKER ARMS 162
Removal 162
Inspection 163
Installation 163
CAMSHAFT 166
Removal And Installation 166
Inspection 166
CYLINDER HEAD 167
Removal And Installation 167
Inspection 168
VALVES 169
Removal 169
Installation 169
Reconditioning The Valve And Valve Seat 170
Valve Seat Inserts 170
Valve Guide 171
Valve Spring 171
PISTON AND CONNECTING ROD 173
Removal 173
Disassembly 173
Inspection 174
Assembly 174
Installation 175
PISTON PIN 177
Assembly Of The Tool 177
Removal Of The Piston Pin 177
Installation Of The Piston Pin 178
CYLINDER LINERS 179
Checking 179
CRANKSHAFT AND MAIN BEARINGS 180
Description 180
Removal 180
Checking 180
Checking Oil Clearance (Plastic Gauge) 181
Installation 181
Crankshaft End Play 182
Rear Oil Seal 182
TIMING BELT 183
Adjustment 183
Removal 184
Inspection 185
Assembly 186
FRONT CASE AND OIL PAN 188
Removal And Installation 188
OIL PUMP 189
Removal 189
Inspection 189
Installation 189
Relief Valve 190
FRONT CASE SEAL 191
Removal And Installation 191
WATER PUMP 192
Removal And Installation 192
Inspection 192
THERMOSTAT 193
Removal And Installation 193
Inspection 193
ANTI–DIESEL SYSTEM 194
Function 194
Removal and Installation 194
SPECIFICATIONS 195
LOADER SPECIFICATIONS 197
OPERATIONS & PERFORMANCE 197
ENGINE 197
HYDRAULIC SYSTEM 198
ELECTRICAL 198
DRIVE SYSTEM 198
CAPACITIES 198
TIRES 198
ENGINE SPECIFICATIONS 199
General 199
Cylinder Head 199
Cylinder Block 199
Piston 199
Piston Pin 199
Connecting Rod 200
Crankshaft 200
Flywheel 200
Camshaft 200
Valve Train 200
Valve Guide 201
Valve Spring 201
Rocker Arm and Shaft 202
Oil Pump 202
Fuel Pump 202
Carburetor 202
Water Pump 202
Thermostat 202
Starter 203
Alternator 203
Distributor 203
Spark Plug 203
Engine Torque 203
TORQUE FOR GENERAL METRIC BOLTS 204
TORQUE SPECIFICATIONS FOR LOADER 205
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 206
Specifications 206
DECIMAL AND MILLIMETER EQUIVALENTS 207
U S TO METRIC CONVERSION 207
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 208
SERVICE MANUAL REVISIONS 209
642B-1 209
642B-2 211
642B-3 213
642B-4 215
642B-5 217
642B-6 219
642B-7 221
642B-8 223
642B-9 225
642B-10 227
642B-11 229

DESCRIPTION:

Bobcat 642B Loader Service Manual 6570275 (6-12) – PDF DOWNLOAD

FOREWORD:

This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS:

The following publications provide information on the safe use and maintenance of the loader and attachments:
1. The Delivery Report is used to assure that complete instructions have been given to the new owner and
that the machine is in safe operating condition.
2. The Operation & Maintenance Manual delivered with the loader gives operating information as well as
routine maintenance and service procedures. It is a part of the loader and must stay with the machine when
it is sold. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
3. The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their
locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your
Bobcat loader dealer.
4. The FIEI Safety Manual delivered with the loader gives general safety information.
5. The Service Manual and Parts Manual are available from your dealer for use by mechanics to do
shop–type service and repair work.

Wear tight fitting clothing and any other required safety apparel when operating or servicing the loader.
• Wear safety glasses when maintaining or servicing the loader.
• Exhaust gases can kill, vent engine exhaust outdoors.
• Know where fire extinguishers and first aid kits are located and how to use them.
• Do not run the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive
dust or gases.
• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel
for cleaning parts. Use commercial nonflammable solvents.
• Clean the loader before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher
near the loader when welding
• Have good ventilation when welding or grinding painted parts. Wear a dust mask when grinding painted parts. Toxic dust
and gas can be produced.
• Stop the engine and let it cool before adding fuel. No smoking.
• Use the procedure in this manual for connecting and charging batteries.J
• Use the procedure in the Operator’s Manual for cleaning the spark arrestor muffler after each 100 hours of operation.

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