Description
Bobcat 641, 642, 643 Skid Steer Loader Service Manual
Condition: Brand New
Language: English
Manufacturer: Bobcat
Models Covered: 641, 642, 643
Serial Numbers Covered: nan
Manual Type: Service Manual
Manufacturer Part Number: 6566135_10_86
Pages: 384
Format: PDF Instant View+Download
A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.
An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.
A Parts Catalog is often large and broken down in to sections for
different parts of your
equipment. Parts Catalogs cover absolutely every aspect of your machine unless
mentioned
otherwise. Sometimes, the engine is covered in a separate parts catalog that is
written
specifically for the engine. Most of the time though, it’s included in the main
parts
catalog. A parts catalog will arm you with the same exact information that your
local
service center has and includes exploded views of assemblies that are a great
help with
disassembly and re-assembly. Parts catalogs also include all part numbers for
every part
of your machine which makes for easy ordering of parts.
PDF Contents:
- 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
- BOBâTACH
- 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 OâRing 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 BYâPASS VALVE
- Removing ByâPass Valve
- Installation Of The ByâPass 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 ByâPass Valve
- Neutral ByâPass Valve
- Removing The Port Block
- Installing The Port Block
- HYDROSTATIC MOTOR
- Removing The Hydrostatic Motor (Model 109â1174â006 & Above)
- Removing The Hydrostatic Motor (Model 109â1052â006 & Below)
- Disassembly Of The Hydrostatic Motor
- Hydrostatic Motor Inspection
- Assembly Of The Hydrostatic Motor
- Installing The Hydrostatic Motor (Model 109â1173â006 & Above) (Splined Shaft)
- Installing the Hydrostatic Motor (Model 109â1052â006 & Below)
- StartâUp 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
- BOBâTACH FRAME (40 Series)
- Removing The BobâTach
- Disassembly Of The BobâTach
- Assembly Of The BobâTach
- Installing The BobâTach
- 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
- BOBâTACH (50 Series)
- Removal And Installation
- BobâTach 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 UâJoint
- Installing The UâJoint
- 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 â 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
- 640â5
- 640â6
- 640â7
- 640â8
- 640â9
- 640â10
- 640â11
- 640â12
- 640â13
- 640â14
- 640â15
- 640â16
- 640â17
- 640â18
- 640â19
- 640â20
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