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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