Bobcat 645 Loader Service Manual 6722526 – PDF DOWNLOAD

Description

Bobcat 645 Loader Service Manual 6722526 – PDF DOWNLOAD

FILE DETAILS:

Bobcat 645 Loader Service Manual 6722526 – PDF DOWNLOAD

Language : English
Pages : 196
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 645 Loader Service Manual 6722526 – PDF DOWNLOAD

MAINTENANCE SAFETY 2
FOREWORD 5
CONTENTS 7
SAFETY INSTRUCTIONS 9
SERIAL NUMBER LOCATIONS 10
LOADER SERIAL NUMBER 10
ENGINE SERIAL NUMBER 10
DELIVERY REPORT 10
BOBCAT SKID STEER LOADER IDENTIFICATION 11
PREVENTIVE MAINTENANCE 13
SERVICE SCHEDULE 15
PREVENTIVE MAINTENANCE 16
LIFTING AND BLOCKING THE BOBCAT LOADER 16
Procedure 16
PARKING THE BOBCAT LOADER 17
Procedure 17
TRANSPORTING THE BOBCAT LOADER 17
LIFT ARM SUPPORT DEVICE 18
To Engage Lift Arm Support Device 18
To Disengage Lift Arm Support Device 18
OPERATOR CAB 19
Description 19
Raising the Operator Cab 19
Lowering the Operator Cab 19
SEAT BAR RESTRAINT SYSTEM 20
Description 20
Seat Bar Inspection 21
Seat Bar Maintenance 21
AIR CLEANER SERVICE 22
Replacement of the Filter Element 22
FUEL SYSTEM 24
Fuel Specifications 24
Filling the Fuel Tank 24
Fuel Filter 24
Removing Air From the Fuel System 25
ENGINE LUBRICATION SYSTEM 26
Checking Engine Oil 26
Replacing Oil and Filter 26
ENGINE COOLING SYSTEM 28
Coolant Level 28
Cleaning the Cooling System 28
Removing Coolant from the Cooling System 28
ALTERNATOR BELT ADJUSTMENT 30
Adjusting the Alternator Belt 30
USING A BOOSTER BATTERY (JUMP STARTING) 31
Procedure 31
HYDRAULIC / HYDROSTATIC SYSTEM 32
Checking and Adding Fluid 32
Hydraulic / Hydrostatic Filter Replacement 33
Removing the Hydraulic Fluid 33
SPARK ARRESTOR MUFFLER 34
Cleaning Procedure 34
TIRE MAINTENANCE 35
Wheel Nuts 35
Tire Rotation 35
Tire Mounting 35
FINAL DRIVE TRANSMISSION (CHAINCASE) 36
Checking and Adding Oil 36
LUBRICATION OF THE BOBCAT LOADER 37
Procedure 37
U-JOINTS LUBRICATION 39
Procedure 39
REMOTE START SWITCH 39
Procedure 39
HYDRAULIC SYSTEM 41
HYDRAULIC / HYDROSTATIC SCHEMATICS 43
HYDRAULIC SYSTEM 47
TROUBLESHOOTING 47
HYDRAULIC SYSTEM INFORMATION 48
Flare Connections 48
O-ring Face Seal Connections 48
Straight Thread O-ring Fitting 48
Tubelines and Hoses 48
LIFT CYLINDER 49
Checking the Lift Cylinder(s) 49
Removal and Installation 49
TILT CYLINDER 51
Checking the Tilt Cylinder 51
Removal and Installation 51
HYDRAULIC CONTROL VALVE 53
Checking the Main Relief Valve W/Auxiliary Couplers (Opt ) 53
Main Relief Valve Removal and Installation 54
Adjusting the Main Relief Valve 54
Removal and Installation 55
HYDRAULIC PUMP 57
Checking the Output of the Hydraulic Pump 57
Removal and Installatio n 58
PORT BLOCK 59
Removal and Installation 59
Cold Weather By-Pass Valve 60
Case Drain Relief Valve 61
HYDRAULIC FLUID RESERVOIR 62
Removal and Installation 62
HYDRAULIC CONTROL PEDALS 63
Removal and Installation 63
Adjustment 63
PEDAL INTERLOCK LINKAGE 64
Installation 64
Adjustment 64
HYDRAULIC FLUID FILTER HOUSING 65
By-Pass Removal and Installation 65
HYDROSTATIC SYSTEM 67
TROUBLESHOOTING 69
HYDROSTATIC SYSTEM INFORMATION 70
High Pressure Relief / Replenishing Valve Function 70
FRONT PANEL 71
Removal and Installation 71
STEERING LEVERS 73
Removal and Installation 73
Repairing the Steering Levers 74
STEERING LINKAGE 75
Steering Linkage Adjustment 75
Removal and Installation 76
Repairing the Pintle Lever 77
HYDROSTATIC MOTOR 78
Removal and Installation 78
HYDROSTATIC PUMP 80
Checking Charge Pressure 80
Charge Pressure Relief Valve 80
Checking High Pressure Relief Valves 81
Removal and Installation 82
Hydrostatic Pump Rear Mount 85
High Pressure Hose Routing 85
Tow Valves 85
DRIVE SYSTEM 87
PARKING BRAKE 89
Adjustment 89
Removal and Installation 90
Brake Block and Pads 91
Brake Discs Removal and Installation 93
MOTOR CARRIER 94
Shaft Seal Replacement 94
Removal and Installation 96
Disassembly and Assembly 97
AXLE SEAL 98
Removal and Installation 98
AXLE, SPROCKET AND BEARINGS 101
Removal and Installation 101
DRIVE CHAIN 105
Removal and Installation 105
CHAINCASE FLUID 106
Replacing the Chaincase Fluid 106
MAIN FRAME 107
OPERATOR CAB 109
Removal and Installation 109
OPERATOR CAB GAS CYLINDER 112
Removal and Installation 112
REAR DOOR 113
Door Latch Adjustment 113
Removal and Installation 114
REAR GRILLE 115
Removal and Installation 115
BOB-TACH 116
Removal and Installation 116
Bob-Tach Lever and Wedge 119
LIFT ARMS 121
Removal and Installation 121
FUEL TANK 123
Removal and Installation 123
Fuel Tank Sender Switch 124
ELECTRICAL SYSTEM 125
ELECTRICAL SCHEMATICS 127
ELECTRICAL SYSTEM INFORMATION 131
Description 131
TROUBLESHOOTING 131
BATTERY 132
Checking the Battery 132
Removal and Installation 132
ALTERNATOR BELT SHIELD 133
Removal and Installation 133
ALTERNATOR 134
Alternator Output Test 134
Rectifier (Diode) Test 134
Alternator Regulator Test 135
Removal and Installation 136
Disassembly and Assembly 137
Stator Continuity Test 137
Stator Ground Test 137
Rotor Continuity Test 137
Rotor Gound Test 137
Rectifier Continuity (Diode) Test 138
Parts Identification 139
STARTER 140
Checking the Starter 140
Removal and Installation 140
Disassembly and Assembly 141
Replacing the Brushes 142
Cleaning and Inspection 143
Parts Identification 144
ENGINE SERVICE 145
TROUBLESHOOTING 147
FUEL FILTER 148
Replacing the Fuel Filter 148
Removing Air From the Fuel System 148
GLOW PLUGS 148
Checking 148
FUEL INJECTION PUMP 149
Removal and Installation 149
Timing the Injection Pump 150
Checking the Injection Pump 151
FUEL INJECTOR NOZZLES 152
Removal and Installation 152
Checking the Nozzles 153
ENGINE 154
Removal and Installation 154
RADIATOR AND OIL COOLER 156
Removal and Installation 156
BLOWER HOUSING 157
Removal and Installation 157
ENGINE FLYWHEEL AND U-JOINT 158
Removal and Installation 158
Flywheel Ring Gear 158
MUFFLER 159
Removal and Installation 159
CYLINDER HEAD 160
Removal 160
Disassembly 161
Servicing 161
Valve Guide Installation 163
Assembly 165
Installation 165
ENGINE REPAIR 166
Gearcase Removal 166
Timing Gear, Camshaft and Oil Pump Removal 168
Pistons and Crankshaft Removal 169
Timing Gear and Camshaft Service 171
Servicing the Connecting Rods and Pistons 172
Crankshaft Service 174
Cylinder Liner Service 175
Lubrication System 176
Oil Pump Service 177
Water Pump Service 177
ENGINE ASSEMBLY 179
Crankshaft Installation 179
Installing the Pistons 179
Installing the Camshaft and Timing Gears 179
Gearcase Installation 181
SPECIFICATIONS 183
LOADER SPECIFICATIONS 185
LOADER DIMENSIONS 185
OPERATION & PERFORMANCE 185
ENGINE 185
HYDRAULICS SYSTEM 186
ELECTRICAL 186
DRIVE SYSTEM 186
CAPACITIES 186
TIRES 186
ENGINE SPECIFICATIONS 187
Fuel Injection Nozzles 187
Fuel Injection Pump 187
Cylinder Head 187
Valves 187
Valve Springs 187
Rocker Arms 187
Camshaft 187
Cylinders 188
Piston Rings 188
Pistons 188
Crankshaft 188
Oil Pump 188
Engine Oil 188
ENGINE BOLT TORQUES 189
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 191
Specifications 191
DECIMAL AND MILLIMETER EQUIVALENTS 192
U S TO METRIC CONVERSION 192
TORQUE FOR GENERAL METRIC BOLTS 193
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 194

DESCRIPTION:

Bobcat 645 Loader Service Manual 6722526 – 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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