Complete repair service manual with Electrical Wiring Diagrams for Bobcat Skid-Steer Loaders 641, 642, 642B, 643, 645, with workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Bobcat Skid-Steer Loaders 641, 642, 642B, 643, 645 workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6556850 (6-82) - 641 Operator's Manual.pdf
6556852 (6-82) - 642 Operation & Maintenance Manual.pdf
6556854 (6-82) - 643 Operator's Manual.pdf
6566135 (6-12) - 641, 642, 643 Service Manual.pdf
6566135 (10-86) - 641, 642, 643 Service Manual.pdf
6566557 (4-83) - 643 Operator's Manual.pdf
6566561 (2-83) - 641 Operator's Manual.pdf
6566562 (2-83) - 642 Operator's Manual.pdf
6566706 (4-84) - 641 Operator's Manual.pdf
6566707 (3-84) - 642 Operator's Manual.pdf
6566708 (10-98) - 643 Operation & Maintenance Manual.pdf
06570241 (8-96) - 641, 642, 642B, 643 Operation & Maintenance Manual.pdf
6570246 (4-87) - 642B Operator's Manual.pdf
6570275 (4-86) - 642B Service Manual.pdf
6570275 (6-12) - 642B Service Manual.pdf
6720910 (10-91) - 642B, 742B, 743B Hand Controls Operation & Maintenance Manual.pdf
6722526 (03-93) - 645 Service Manual.pdf

Total Pages: 2,321
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

TABLE CONTENTS
06570241 (8-96) - 641, 642, 642B, 643 Operation & Maintenance Manual...1
  OPERATOR SAFETY WARNINGS...3
  CONTENTS...5
    REFERENCE INFORMATION...5
  FOREWORD...7
    SERIAL NUMBER LOCATIONS...9
    LOADER SERIAL NUMBER...9
    ENGINE SERIAL NUMBER...9
    DELIVERY REPORT...9
    BOBCAT LOADER IDENTIFICATION...10
    OPTIONS AND ACCESSORIES...11
  SAFETY...13
    BEFORE OPERATING THE BOBCAT LOADER...15
    SAFE OPERATION NEEDS A QUALIFIED OPERATOR*...15
    SAFETY INSTRUCTIONS...16
    SAFETY IS THE OPERATOR’S RESPONSIBILITY...16
    FIRE PREVENTION...17
    MACHINE SIGNS (DECALS)...18
  OPERATING INSTRUCTIONS...21
    INSTRUMENT PANEL...23
      One Piece...23
      Three Piece...24
    LEARNING THE CONTROLS...25
    ENGINE SPEED CONTROL...25
    CHOKE CONTROL (642 & 642B)...25
    STOPPING THE ENGINE (641, 642 & 642B)...25
    ENGINE STOP CONTROL (643)...25
    PARKING BRAKE...25
    STEERING LEVERS...26
    HYDRAULIC CONTROLS...27
      Foot Pedals...27
      Lift Arm Operation...27
      Tilt Operation (Bucket)...27
      Lift Arm Float Position...27
      Auxiliary Lever Operation (Optional on 642B)...27
    DAILY INSPECTION...28
    SEAT BAR RESTRAINT SYSTEM...29
    GETTING READY FOR OPERATION...30
      Getting On And Off The Loader...30
      Machine Signs (Decals)...31
    STARTING THE ENGINE...32
      Normal Starting Condition...32
      Cold Temperature Starting Condition...34
    ATTACHMENTS AND BUCKETS...35
      Installation And Removal (641, 642, 643) (Optional on 642B)...35
      Installation Of Attachment (642B Standard)...37
      Installation Of Bucket (642B)...37
      Removal Of Bucket (642B)...37
    OPERATING PROCEDURES...38
      Filling The Bucket...39
      Emptying The Bucket...39
      Digging Into The Ground...40
      Leveling The Ground (Using Lift Arms In FloatPosition)...41
      Backfilling...41
    PARKING THE BOBCAT LOADER...42
    STOPPING THE BOBCAT LOADER...42
    TRANSPORTING THE BOBCAT LOADER...42
    TOWING THE BOBCAT LOADER...43
    LIFTING THE BOBCAT LOADER...44
  PREVENTIVE MAINTENANCE...45
    MAINTENANCE SAFETY...46
    SERVICE SCHEDULE...47
    LIFT ARM SUPPORT DEVICE...48
    OPERATOR CAB...49
      Raising The Operator Cab...49
      Lowering The Operator Cab...50
    SEAT BAR RESTRAINT SYSTEM...51
      Inspecting The Seat Bar...51
      Maintaining The Seat Bar...51
    REAR DOOR...52
      Opening The Rear Door...52
      Adjusting The Rear Door...52
    AIR CLEANER SERVICE...53
    FUEL SYSTEM...55
      Fuel Specifications...55
      Fuel Filter (641 & 643 Only)...56
      Fuel Filter (642 & 642B Only)...56
      Removing Air From The Fuel System (641)...57
      Removing Air From The Fuel System (643)...57
    ENGINE LUBRICATION SYSTEM...58
      Checking Engine Oil...58
      Replacement Of Oil And Filter...59
    COOLING SYSTEM...60
      Cleaning The Cooling System...60
      Checking The Coolant Level...60
      Removing Coolant From The Cooling System...61
    ALTERNATOR BELT...63
      Adjusting The Alternator Belt...63
    GOVERNOR (642 & 642B)...65
      Rod Adjustment...65
      Governor Oil Level...65
    ELECTRICAL SYSTEM...73
      Description...73
      Servicing The Electrical System...73
      Using An Extra Battery (Jump Starting)...73
      Removing And Installing The Battery...75
    SPARK ARRESTOR MUFFLER...77
    HYDRAULIC/HYDROSTATIC SYSTEM...79
      Hydraulic/Hydrostatic Fluid Reservoir...79
      Checking And Adding Fluid...79
      Hydraulic/Hydrostatic Fluid Replacement...79
      Hydraulic/Hydrostatic Filter Replacement...80
    FINAL DRIVE TRANSMISSION (Chaincase)...81
    TIRE MAINTENANCE...82
      Tire Rotation...82
      Tire Mounting...82
      Wheel Nuts...82
    LUBRICATION OF THE BOBCAT LOADER...83
    BOB–TACH...84
    AUXILIARY CONTROL LOCKBOLT...85
    PIVOT PINS...85
    BRAKE PEDAL ADJUSTMENT...85
  TROUBLESHOOTING...87
    TROUBLESHOOTING THE ENGINE...89
    TROUBLESHOOTING THE DRIVE SYSTEM...90
    MCORRECTIONCAUSEPAGETROUBLESHOOTING THE HYDRAULIC SYSTEM...91
  MACHINE SIGN TRANSLATIONS...93
    IMPORTANT - 6560573...95
    WARNING - 6579511...96
    SERVICE SCHEDULE - 6567875...97
    WARNING - 6579510...99
    WARNING - 6579528...100
    DANGER - 6579639 ...100
    DANGER -  6579509...100
  SPECIFICATIONS...101
    641, 642, 643 LOADER SPECIFICATIONS...103
      LOADER DIMENSIONS...103
      OPERATION & PERFORMANCE...103
      ENGINE...103
      HYDRAULIC SYSTEM...104
      ELECTRICAL...104
      DRIVE SYSTEM...104
      CAPACITIES...104
      TIRES...104
      MACHINE WEIGHT (without attachment)...104
    642B LOADER SPECIFICATIONS...105
      LOADER DIMENSIONS...105
      OPERATION & PERFORMANCE...105
      ENGINE...105
      HYDRAULIC SYSTEM...106
      ELECTRICAL...106
      DRIVE SYSTEM...106
      CAPACITIES...106
      TIRES...106
    ADDITIONAL PUBLICATIONS...107
  WARRANTY...109
6556850 (6-82) - 641 Operator's Manual...111
  WARNINGS...112
  SAFETY INSTRUCTIONS...113
  FOREWORD...115
    CONTENTS...115
    641 BOBCAT LOADER IDENTIFICATION...116
  OPERATING INSTRUCTIONS...117
    OPERATING INSTRUCTIONS...119
    CONTROLS...120
    DECAL LOCATION...121
    DASH PANEL...122
    THROTTLE CONTROL...122
    STOPPING THE ENGINE...122
    PARKING BRAKE...122
    STEERING LEVERS...123
    HYDRAULIC CONTROLS...124
      Foot Pedals (Hydraulic)...124
      Lift Arm Operation...124
      Float Position...124
      Tilt (Bucket) Operation...124
      Auxilisry Lever...125
    BEFORE YOU START THE ENGINE...125
    STARTING THE ENGINE...126
      Normal Starting Condition...127
      Easier Starting In Cold Temperature...127
      Cold Temperature Starting...128
    BOBCAT LOADER OPERATION...128
      Bucket Size...128
      Installation Of Attachments...129
      Removal Of Attachments...129
    OPERATING PROCEDURE...130
      Filling The Bucket...131
      To Empty The Bucket...131
      Digging Into The Ground...132
      Making The Ground Level Using Float Position...132
      Filling A Hole...132
    STOPPING THE BOBCAT LOADER...133
    TRANSPORTING THE BOBCAT LOADER...133
    LIFT ARM STOP...134
    LIFTING THE OPERATOR GUARD...135
    LOWERING THE OPERATOR GUARD...135
  PREVENTIVE MAINTENANCE...137
    WARNINGS...138
    SERVICE SCHEDULE...139
    ENGINE SERVICE...140
    ADJUSTING DOOR LATCH...140
    AIR CLEANER SERVICE...140
    FUEL SYSTEM...141
    FUEL SYSTEM SERVICE...141
    FUEL FILTER...141
    REMOVING AIR FROM THE FUEL SYSTEM...142
    ENGINE LUBRICATION SYSTEM...142
    REPLACEMENT OF ENGINE OIL AND FILTER...143
    ENGINE COOLING SYSTEM...143
    ALTERNATOR BELT...144
    ELECTRICAL SYSTEM...144
    USING AN EXTRA BATTERY (JUMP STARTING)...147
    TO INSTALL A NEW BATTERY...149
    SPARK ARRESTOR MUFFLER...149
    HYDRAULIC SYSTEM...150
    HYDRAULIC/HYDROSTATIC OIL RESERVOIR...151
      Checking And Adding Oil...151
      Removing Hydraulic Oil...152
    REPLACEMENT OF THE HYDRAULIC FILTER...152
    FINAL DRIVE TRANSMISSION (CHAINCASE)...152
    TO DRAIN CHAINCASE OIL...153
    TIRE MAINTENANCE...153
      Tire Rotation...153
    LUBRICATION OF THE BOBCAT LOADER...154
    OPERATOR GUARD...155
    BOB-TACH...155
    PIVOT PINS...156
    AUXILIARY CONTROL LOCKBOLT...156
    BRAKE PEDAL ADJUSTMENT...156
    DELIVERY REPORT...157
  TROUBLESHOOTING...159
    TROUBLESHOOTING THE ENGINE...161
    TROUBLESHOOTING THE DRIVE SYSTEM...162
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...163
  MAJOR PARTS...165
    MAIN FRAME...167
    PANELS, SEAT, SEAT BAR & FUEL SYSTEM...168
    DRIVE SYSTEM...169
    HYDRAULIC SYSTEM...170
    CONTROL PEDALS...171
    HYDROSTATIC SYSTEM...172
    HAND CONTROLS...173
    OPERATOR GUARD ELECTRICAL SYSTEM...174
    ENGINE ELECTRICAL SYSTEM...175
    ENGINE & ATTACHING PARTS...176
    DECALS...178
  DECALS...179
    WARNING - 6563484...181
    SERVICE SCHEDULE - 6561387...182
    WARNING - 6561380...184
    WARNING - 6563380...185
    IMPORTANT - 6560573...186
  GENERAL INFORMATION...187
    LOADER SPECIFICATIONS...189
    OPERATION & PERFORMANCE...189
    ENGINE...189
    HYDRAULIC SYSTEM...190
    HYDRAULIC CYLINDERS...190
    HYDROSTATIC TRANSMISSION & FINAL DRIVE...190
    ELECTRICAL...190
    TIRES...190
    FLUID CAPACITIES...190
    ADDITIONAL PUBLICATIONS...191
6556852 (6-82) - 642 Operation & Maintenance Manual...193
  WARNINGS...195
  FOREWORD...197
    CONTENTS...197
    REFERENCE INFORMATION...197
    642 BOBCAT LOADER IDENTIFICATION...199
    SAFETY INSTRUCTIONS...201
  OPERATING INSTRUCTIONS...203
    OPERATING INSTRUCTIONS...205
    CONTROLS...206
    DECAL LOCATIONS...207
    DASH PANEL...208
    THROTTLE CONTROL...208
    CHOKE CONTROL...208
    STOPPING THE ENGINE...208
    PARKING BRAKE...208
    STEERING LEVERS...209
    HYDRAULIC CONTROLS...210
      Foot Pedal (Hydraulic)...210
      Lift Arm Operation...210
      Float Postion...210
      Tilt (Bucket) Operation...210
      Auxiliary Lever...211
    BEFORE YOU START THE ENGINE...211
    STARTING THE ENGINE...212
      Normal Starting Condition...213
      Cold Temperature Starting Condition...213
    BOBCAT LOADER OPERATION...214
      Bucket Size...214
      Installation Of Attachments...215
      Removal Of Attachments...215
    OPERATING PROCEDURE...216
      Filling The Bucket...217
      To Empty The Bucket...217
      Digging Into The Ground...218
      MakingTjne Ground Level Using Float Position...218
      Filling A Hole...218
    STOPPING THE BOBCAT LOADER...219
    TRANSPORTING THE BOBCAT LOADER...219
    LIFT ARM STOP...220
    LIFTING THE OPERATOR GUARD...221
    LOWERING THE OPERATOR GUARD...221
  PREVENTIVE MAINTENANCE...223
    WARNINGS...224
    SERVICE SCHEDULE...225
    ENGINE SERVICE...226
    ADJUSTING DOOR LATCH...226
    AIR CLEANER SERVICE...226
    FUEL SYSTEM...227
    FUEL SYSTEM SERVICE...227
    FUEL FILTER...228
    ENGINE LUBRICATION SYSTEM...228
    REPLACEMENT OF ENGINE OIL AND FILTER...228
    COOLANT LEVEL...229
    REMOVING COOLANT FROM THE COOLING SYSTEM...230
    DRIVE BELTS...230
    ELECTRICAL SYSTEM...231
    USING AN EXTRA BATTERY (JUMP STARTING)...234
    INSTALLING A NEW BATTERY...235
    SPARK ARRESTOR MUFFLER...236
    HYDRAULIC SYSTEM...236
    HYDRAULIC/HYDROSTATIC SYSTEM OIL RESERVOIR...236
      Checking And Adding Oil...238
      Removing Hydraulic Oil...238
    REPLACEMENT OF THE HYDRAULIC FILTER...239
    FINAL DRIVE TRANSMISSION (CHAINCASE)...239
    TIRE MAINTENANCE...239
      Tire Rotation...240
    LUBRICATION OF THE BOBCAT LOADER...240
    OPERATOR GUARD (ROPS & FOPS)...241
    BOB-TACH...242
    PIVOT PINS...242
    AUXILIARY CONTROL LOCKBOLT...242
    BRAKE PEDAL ADJUSTMENT...242
    DELIVERY REPORT...243
  TROUBLESHOOTING...245
    TROUBLESHOOTING THE ENGINE...247
    TROUBLESHOOTING THE DRIVE SYSTEM...248
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...249
  MAJOR PARTS...251
    MAIN FRAME...253
    PANELS, SEAT, SEAT BAR & FUEL SYSTEM...254
    DRIVE SYSTEM...255
    HYDRAULIC SYSTEM...256
    HYDROSTATIC SYSTEM...257
    HAND CONTROLS...258
    OPERATOR GUARD ELECTRICAL SYSTEM...259
    ENGINE ELECTRICAL SYSTEM...260
    ENGINE & ATTACHING PARTS...261
    DECALS...263
  DECALS...265
    WARNING - 6563484...267
    SERVICE SCHEDULE - 6541387...268
    WARNING -6561380...270
    WARNING - 6563380...271
    IMPORTANT - 6560573...272
  GENERAL INFORMATION...273
    LOADER SPECIFICATIONS...275
    OPERATION & PERFORMANCE...275
    ENGINE...275
    HYDRAULIC SYSTEM...275
    HYDRAULIC CYLINDERS...276
    HYDROSTATIC TRANSMISSION & FINAL DRIVE...276
    ELECTRICAL...276
    TIRES...276
    FLUID CAPACITIES...276
    ADDITIONAL PUBLICATIONS...277
  WARRANTY...279
6556854 (6-82) - 643 Operator's Manual...281
  WARNINGS...283
  SAFETY INSTRUCTIONS...285
    SAFETY IS YOUR RESPONSIBILITY...285
    BEFORE YOU OPERATE THE BOBCAT LOADER...285
  FOREWORD...287
    CONTENTS...287
    REFERENCE INFORMATION...287
    643 BOBCAT LOADER IDENTIFICATION...288
  OPERATING INSTRUCTIONS...289
    OPERATING INSTRUCTIONS...291
    CONTROLS...292
    DECAL LOCATIONS...293
    DASH PANEL...294
    THROTTLE CONTROL...294
    STOPPING THE ENGINE...294
    PARKING BRAKE...294
    STEERING LEVERS...295
    HYDRAULIC CONTROLS...296
      Foot Pedals (Hydraulic)...296
    BEFORE YOU START THE ENGINE...297
    STARTING THE ENGINE...298
      Normal Starting Condition...299
      Cold Temperature Starting Condition...299
    BOBCAT LOADER OPERATION...300
      Bucket Size...300
      Installation Of Attachments...301
      Removal Of Attachments...301
    OPERATING PROCEDURE...302
      Filling The Bucket...303
      To Empty The Bucket...303
      Digging Into The Ground...304
      Making The Ground Level Using Float Position...304
      Filling A Hole...304
    STOPPING THE BOBCAT LOADER...305
    TRANSPORTING THE BOBCAT LOADER...305
    LIFT ARM STOP...306
    LIFTING THE OPERATOR GUARD...306
    LOWERING THE OPERATOR GUARD...307
  PREVENTIVE MAINTENANCE...309
    WARNINGS...310
    SERVICE SCHEDULE...311
    ENGINE SERVICE...312
    ADJUSTING DOOR LATCH...312
    AIR CLEANER SERVICE...312
    FUEL SYSTEM...313
    FUEL SYSTEM SERVICE...313
    FUEL FILTER...313
    REMOVING AIR FROM THE FUEL SYSTEM...314
    ENGINE LUBRICATION SYSTEM...314
    REPLACEMENT OF ENGINE OIL AND FILTER...315
    COOLANT LEVEL...315
    REMOVING COOLANT FROM THE COOLING SYSTEM...316
    ALTERNATOR BELT...316
    ELECTRICAL SYSTEM...316
    USING AN EXTRA BATTERY (JUMP STARTING)...319
    TO INSTALL A NEW BATTERY...320
    SPARK ARRESTOR MUFFLER...321
    HYDRAULIC SYSTEM...321
    HYDRAULIC/HYDROSTATIC OIL RESERVOIR...321
      Checking And Adding Oil...323
      Removing Hydraulic Oil...323
    REPLACEMENT OF THE HYDRAULIC FILTER...324
    FINAL DRIVE TRANSMISSION (CHAINCASE)...324
    TIRE MAINTENANCE...324
      Tire Rotation...325
      Wheel Nuts...325
    LUBRICATION OF THE BOBCAT LOADER...325
    ROLL OVER PROTECTION STRUCTURE (ROPS & FOPS)...326
    DELIVERY REPORT...327
    THIRTY HOUR INSPECTION...328
  TROUBLESHOOTING...329
    TROUBLESHOOTING THE ENGINE...329
    TROUBLESHOOTING THE DRIVE SYSTEM...330
    TROUBLSHOOTING THE HYDRAULIC SYSTEM...331
  MAJOR PARTS...333
    MAIN FRAME...335
    DRIVE SYSTEM...337
    HYDRAULIC SYSTEM...339
    HYDROSTATIC SYSTEM...341
    ELECTRICAL SYSTEM...343
    POWER UNIT...345
    DECALS...347
  DECALS...349
    WARNING - 6563484...351
    SERVICE SCHEDULE - 6561387...352
    WARNING - 6561380...354
    WARNING - 6563380...355
    IMPORTANT - 6560573...356
  GENERAL INFORMATION...357
    LOADER SPECIFICATIONS...359
    WEIGHTS...359
    SPEED...359
    ENGINE...359
    LOADER HYDRAULICS...359
    DRIVE SYSTEM...360
    ELECTRICAL...360
    TIRES...360
    FLUID CAPACITIES...360
    ADDITIONAL PUBLICATIONS...361
  WARRANTY...363
6566135 (10-86) - 641, 642, 643 Service Manual...365
  MAINTENANCE SAFETY...367
  SAFETY INSTRUCTIONS...369
    SAFETY IS YOUR RESPONSIBILITY...369
    BEFORE YOU WORK ON THE BOBCAT LOADER...369
  CONTENTS...371
    FOREWORD...371
  PREVENTIVE MAINTENANCE...373
    INTRODUCTION...375
      Serial Number Identification...375
      Loader Serial Number...375
      Engine Serial Number...375
    SERVICE SCHEDULE...377
    ENGINE SERVICE (General)...378
      Opening And Adjusting The Rear Door...378
      Engine Lubrication System...378
      Replacement Of Engine Oil And Filter...379
      Air Cleaner Service...381
    FUEL SYSTEM...382
      Fuel Filter (641)...382
      Fuel Filter (642)...383
      Fuel Filter (643)...383
      Removing Air From The Fuel System (641)...383
      Removing Air From The Fuel System (643)...384
    ENGINE COOLING SYSTEMS...384
      Removing Coolant From The Cooling System...385
    DRIVE BELTS...386
    ELECTRICAL SYSTEM SERVICE ...387
      Using An Extra Battery...387
      Installing A New Battery...388
    HYDRAULIC/HYDROSTATIC SYSTEM...389
    HYDRAULIC/HYDROSTATIC OIL RESERVOIR...389
      Checking And Adding Oil...389
      Removing Hydraulic Oil...390
      Replacement Of The Hydraulic Filter...391
    FINAL DRIVE TRANSMISSION (CHAINCASE)...391
    TIRE MAINTENANCE...391
      Tire Rotation...392
    LUBRICATION OF THE BOBCAT LOADER...392
    OPERATOR GUARD...393
    BOB–TACH...393
    PIVOT PINS...394
    AUXILIARY CONTROL LOCKBOLT...394
    LIFT ARM STOP...394
    SPARK ARRESTOR MUFFLER...395
  HYDRAULIC SYSTEM...397
    HYDRAULIC / HYDROSTATIC SCHEMATICS...399
    TROUBLESHOOTING...423
    HYDRAULIC SYSTEM INFORMATION...424
      37° Flare Connections...424
       Straight Thread O–Ring Fitting...424
      Tubelines And Hoses...424
    HYDRAULIC CONTROL VALVE (Victor)...425
       Relief Valve...425
      Checking The Relief Valve...425
      Removal Of The Relief Valve...426
      Installation Of The Relief Valve...426
      Removal Of The Control Valve...426
       Disassembly Of The Control Valve (Victor)...427
      Assembly And Inspection Of The Control Valve...429
    HYDRAULIC CONTROL VALVE (Melroe)...430
      Relief Valve...430
      Installing A New Relief Valve...430
      Disassembling The Control Valve...430
      Inspecting The Control Valve...433
      Assembling The Control Valve...433
    HYDRAULIC PUMP...436
      Checking Output Of The Hydraulic Pump...436
      Removing The Hydraulic Pump...436
      Checking The Hydraulic Pump...439
      Removing And Checking The Pump Shaft...439
      Installing The Hydraulic Pump...439
      Starting Procedure For The Hydraulic Pump...440
    LIFT CYLINDERS...440
      Checking The Lift Cylinders...440
      Removing The Lift Cylinder...441
      Disassembly Of The Cylinder...442
      Assembly Of The Lift Cylinder...443
      Installation Of The Lift Cylinder(s)...445
    TILT CYLINDER...446
      Checking The Tilt Cylinder...446
      Removing The Tilt Cylinder...446
      Disassembly Of The Tilt Cylinder...447
      Installation Of The Tilt Cylinder...448
    HYDRAULIC/HYDROSTATIC RESERVOIR...448
      Removing The Hydraulic/Hydrostatic Reservoir...448
      Installing The Hydraulic/Hydrostatic Reservoir...448
    OIL COOLER...449
      Removing The Oil Cooler On The 641...449
      Removing The Oil Cooler From The 642 & 643...449
      Installing The Oil Cooler...449
    10 MICRON FILTER BY–PASS VALVE...450
      Removing By–Pass Valve...450
      Installation Of The By–Pass Valve...450
    CONTROL PEDAL, LINKAGE AND LOCKS...450
      Removing Hydraulic Control Pedal...450
      Installing The Hydraulic Control Pedal...451
      Adjusting The Hydraulic Control Pedal...451
      Pedal Lock Linkage...452
  HYDROSTATIC SYSTEM...453
    TROUBLESHOOTING...455
    HYDROSTATIC SYSTEM INFORMATION...456
      Function Of High Pressure Relief Replenishing Valves...456
    STEERING LEVERS...457
      Removing The Steering Levers...457
      Repairing The Steering Levers...458
      Installing The Steering Levers...458
    STEERING LINKAGE...459
      Adjustment Of The Steering Linkage...459
      Removing The Steering Linkage...461
      Repairing The Pintle Lever...461
      Installing The Steering Linkage...462
    PORT BLOCK...462
      40 Micron Filter...462
      Cold Weather By–Pass Valve...463
      Neutral By–Pass Valve...464
      Removing The Port Block...465
      Installing The Port Block...465
    HYDROSTATIC MOTOR...466
      Removing The Hydrostatic Motor (Model 109–1174–006 & Above)...466
      Removing The Hydrostatic Motor (Model 109–1052–006 & Below)...466
      Disassembly Of The Hydrostatic Motor...467
      Hydrostatic Motor Inspection...472
      Assembly Of The Hydrostatic Motor ...473
      Installing The Hydrostatic Motor (Model 109–1173–006 & Above) (Splined Shaft)...478
      Installing the Hydrostatic Motor (Model 109–1052–006 & Below)...478
      Start–Up Procedure For The Hydrostatic Motor...479
    HYDROSTATIC PUMP...479
      Checking The High Pressure Relief Replenishing Valves...479
      Removing The Hydrostatic Pumps...481
      Disassembly Of The Hydrostatic Pump...483
      Hydrostatic Pump Inspection...486
      Assembly Of The Hydrostatic Pump...488
      Installing Pumps To Manifold Block...494
      Installing Hydrostatic Pump Assembly...496
    TOWING THE BOBCAT LOADER...496
  DRIVE SYSTEM...497
    BRAKES...499
      Brake Adjustment...499
      Brake Removal...500
    FINAL DRIVE...502
      Chain Replacement...502
    AXLES AND BEARINGS...503
      Axle And Bearing Removal...503
      Assembly Of The Axles...505
      Installing The Axles...505
    CHAINCASE FLUID...506
      Replacing The Chaincase Fluid...506
  MAIN FRAME...507
    RAISING AND LOWERING THE OPERATOR GUARD...509
      Raising The Operator Guard...509
      Lowering The Operator Guard...509
      Jumper Start Switch...510
    OPERATOR GUARD REMOVAL AND INSTALLATION...510
      Removing The Operator Guard...510
      Operator Guard Installation...511
    BOB–TACH FRAME (40 Series)...511
      Removing The Bob–Tach...511
      Disassembly Of The Bob–Tach...512
      Assembly Of The Bob–Tach...513
      Installing The Bob–Tach...515
    LIFT ARMS...516
      Removing The Lift Arms...516
      Installing The Lift Arms...517
    REAR DOOR...518
      Removing The Rear Door...518
      Installing The Rear Door...518
      Adjusting The Rear Door Latch...518
    FUEL TANK...519
      Removing The Fuel Tank...519
      Installing The Fuel Tank...519
    BOB–TACH (50 Series)...520
      Removal And Installation...520
      Bob–Tach Lever And Wedge...523
  ELECTRICAL SYSTEM...525
    ELECTRICAL SCHEMATICS...528
    TROUBLESHOOTING...551
    ELECTRICAL SYSTEM INFORMATION...552
      Electrical Circuitry...552
      Safety Procedures For The Battery...552
      Alternator Damage...553
    BATTERIES...553
      Checking The Battery...553
    WIRE HARNESS FOR THE OPERATOR GUARD...553
      Removing The Wire Harness For The Operator Guard...553
      Installing The Wire Harness For The Operator Guard...554
    WIRE HARNESS FOR THE ENGINE...555
      Removing The Wire Harness For The Engine...555
      Installing The Wire Harness For The Engine...555
    ALTERNATOR...555
      Checking The Alternator...555
      Removing The Alternator...556
      Repairing The Alternator...557
      Installing The Alternator...559
    STARTER...559
      Checking The Starter...559
      Removing The Starter...560
      Repairing The Starter...560
  ENGINE SERVICE...563
    ENGINE SERVICE (641 DEUTZ)...565
      TROUBLESHOOTING...567
      FUEL SYSTEM...568
        Fuel System Service...568
        Venting Air From The Fuel System...568
        Fuel Filters...569
        Fuel Water Trap...569
        Fuel Lift Pump...570
        Fuel Injection Pump...570
        Removal Of The Injection Pump...570
        Injection Pump Service...570
        Installing The Injection Pump...570
        Checking Adjustment Of Fuel Delivery...572
      FUEL INJECTION NOZZLES...573
        Removal...573
        Disassembly And Repair Of Injector (In The Shop)...573
        Installation Of The Injector...573
      BLOWER FAN...574
        Removal Of The Blower Fan...574
        Disassembly Of The Blower Fan...574
        Assembly Of The Blower Fan...574
        Installation Of The Blower Fan...575
      ENGINE SERVICE...575
      ENGINE REMOVAL...575
      CYLINDER HEAD AND VALVES...578
        Removal And Disassembly...578
        Repair And Assembly...578
        Checking Piston Crown Clearance And Installation Of Cylinder Head...580
      CYLINDER, PISTONS AND CONNECTING RODS...581
        Assembly...582
      OIL PUMP, FILTER HOUSING AND RELIEF VALVE...583
        Oil Pump Removal...583
        Installation...583
        Oil Pressure Relief Valve...583
      ENGINE FRONT COVER...583
        Removal...583
        Disassembly And Inspection...584
        Assembly...584
        Installation...585
      GOVERNOR...586
        Removal And Disassembly...586
        Assembly And Installation...586
      CAMSHAFT...587
        Removal...587
        Installation...587
        Crankshaft Removal...587
        Inspection...588
        Assembly...588
      UNIVERSAL JOINT...589
        Universal Joint Removal...589
        Universal Joint Installation...589
      FLYWHEEL...589
        Flywheel Removal...589
        Flywheel Installation...589
        Removing The Ring Gear...590
      ENGINE OIL COOLER...590
      ENGINE SHROUDING...590
      ENGINE MOUNTS...590
        Replacing Engine Mounts...590
      MUFFLER...591
        Removal Of The Muffler...591
      STARTER...591
        Starter Removal...591
    ENGINE SERVICE (642 FORD)...593
      TROUBLESHOOTING...595
      CHECKS AND ADJUSTMENTS...596
        Oil Pressure...596
        Valve Clearance...596
        Compression...596
        Carburetor, Throttle And Governor Adjustments...597
        Ignition System...599
          Spark Plug Wires Resistance Test...599
          Spark Plug Test...599
          Distributor Tests...599
          Dwell Angle Check...600
          Spark Strength Tests...600
          Battery To Coil Voltmeter Test...600
          Starting Ignition Circuit Voltmeter Test...601
          Breaker Point Gap Adjustment...601
        Ignition Timing...601
      CARBURETOR REPAIR...602
      ENGINE DIAGNOSIS AND TESTING...602
        Camshaft Lobe Lift...602
        Crankshaft End Play...603
        Flywheel Surface Alignment Check...603
        Camshaft End Play...604
      ENGINE REMOVAL...604
      ENGINE REPAIR...606
        Valve Guides...606
        Grinding The Valve Seats...606
        Valves...607
        Grinding Valves...607
        Select Fitting Of The Valves...607
        Camshaft Repair...607
        Crankshaft...607
        Repairing Journals...607
        To Check Crankshaft Or Connection Rod Bearings With Plastigage...607
        Installing Pistons...608
        Installing Piston Rings...609
        Installing The Piston Pins...609
        Valve Rocker Arm And Shaft Assembly...609
        Push Rods...609
      CYLINDER BLOCK...609
        Finishing The Cylinder Walls...609
      CYLINDER HEADS...610
        Cleaning The Cylinder Heads...610
        Checking The Cylinder Heads...610
      TAPPETS...610
        Cleaning The Tappets...610
        Checking The Tappets...611
      CAMSHAFT...611
        Cleaning And Checking The Camshaft...611
      CRANKSHAFT...611
        Checking The Crankshaft...611
      FLYWHEEL...611
        Checking The Flywheel...611
      CONNECTING RODS...611
        Cleaning The Connecting Rods...611
        Checking The Connecting Rods...611
      PISTONS, PINS AND RINGS...612
        Cleaning The Pistons, Pins and Rings...612
        Checking The Pistons, Pins And Rings...612
      MAIN BEARING AND CONNECTING ROD BEARINGS...612
        Cleaning Bearings...612
        Checking Bearings...612
      CYLINDER BLOCK...612
        Cleaning The Cylinder Block...612
        Checking The Cylinder...613
      OIL PUMP...613
        Cleaning The Oil Pump...613
        Checking The Oil Pump...613
      VALVE ROCKER ARM COVER AND ROCKER ARM SHAFT...614
        Removing And Disassembly Of The Rocker Arm Shaft...614
        Installing Rocker Arm Shaft...614
      VALVE PUSHRODS...615
        Removing The Valve Pushrods...615
        Installing The Valve Pushrods...615
      INTAKE MANIFOLD...615
        Removing The Intake Manifold...615
        Installing The Intake Manifold...615
      CYLINDER HEAD...616
        Removing The Cylinder Head...616
        Installing The Cylinder Head...616
      VALVE SPRING, RETAINER AND STEM SEAL (With The Cylinder Head Removed)...617
        Removing The Valve Spring...617
        Installing The Valve Spring...617
      VALVE SPRING, RETAINER AND STEM SEAL (With The Cylinder Head Installed)...617
        Installing The Valve Spring...618
      WATER PUMP...619
        Removing The Water Pump...619
      CYLINDER FRONT COVER, TIMING CHAIN AND CRANKSHAFT SPROCKETS...619
        Removal...619
        Removing The Timing Cover...619
        Installation Of The Timing Cover...620
      FRONT OIL SEAL...620
        Removing The Front Oil Seal...620
      FRONT OIL SEAL...621
        Removing The Oil Seal...621
        Installing The Oil Seal...621
      TIMING CHAIN TIGHTENING...621
        Removing The Chain Tightener...621
        Installing The Chain Tightener...621
      CAMSHAFT AND VALVE LIFTERS...621
        Removing The Camshaft And Valve Lifters...621
        Installing The Camshaft And Valve Lifters...622
      OIL PAN...623
        Removing The Oil Pan...623
        Installing The Oil Pan...624
      OIL PUMP...624
        Removing The Oil Pump...624
        Installing The Oil Pump...624
      CRANKSHAFT REAR OIL SEAL...624
        Removing The Rear Oil Seal...624
        Installing The Rear Oil Seal...625
      MAIN BEARINGS...625
        Removing The Main Bearings...625
        Installing The Main Bearings...625
      CONNECTING ROD BEARINGS...626
        Removing The Connecting Rod Bearings...626
        Installing The Connecting Rod Bearings...626
      PISTONS AND CONNECTING RODS...626
        Removing The Pistons And Connecting Rods...626
        Installing The Pistons And Connecting Rods...627
      CAMSHAFT BEARINGS...627
        Removing The Camshaft...627
      CRANKSHAFT...628
        Installing The Crankshaft...628
      UNIVERSAL JOINT...629
        Universal Joint Installation...629
      FLYWHEEL...629
        Flywheel Removal...629
      FLYWHEEL RING GEAR...630
        Removing The Ring Gear...630
        Installing The Ring Gear...630
      MUFFLER...630
        Removing The Muffler...630
      RADIATOR...630
        Removing The Radiator...630
        Installing The Radiator...632
      BLOWER HOUSING...632
        Removing The Blower Housing...632
        Installing The Blower Housing...633
      STARTER...633
        Removing The Starter...633
        Installing The Starter...633
    ENGINE SERVICE (643 KUBOTA)...635
      TROUBLESHOOTING...637
      FUEL SYSTEM...638
        Replacing The Fuel Filter...638
        To Remove The Air From The Fuel System...638
        Checking Glow Plugs...638
        Removal And Installation Of The Fuel Injection Pump...639
        Timing The Fuel System...640
        Fuel Injector Nozzles...640
      REMOVING AND INSTALLING THE ENGINE...641
        Removing The Engine...641
        Installing The Engine...643
      REPAIRING THE CYLINDER HEAD...644
        Removing The Cylinder Head...644
        Disassembly Of The Cylinder Head...645
        Servicing The Cylinder Head...645
        Assembly Of The Cylinder Head...647
        Installing The Cylinder Head...647
        Adjusting The Compression Release Mechanism (S/N 11620 and Below Only)...648
      REPAIRING THE ENGINE...649
        Removing The Gear Case...649
        Removing The Timing Gear, Camshaft And Oil Pump...650
        Removing Pistons And Crankshaft...651
        Servicing The Timing Gear And Camshaft...652
        Servicing The Connecting Rods And Pistons...653
        Servicing The Crankshaft...654
        Servicing The Cylinder Liners...655
        Servicing The Oil Pump...656
        Servicing The Water Pump...657
      ASSEMBLY OF THE ENGINE...657
        Installing The Crankshaft...657
        Installing Pistons...658
        Installing The Camshaft And Timing Gears...658
        Installing The Gear Case Cover...659
      UNIVERSAL JOINT...660
        Removing The U–Joint...660
        Installing The U–Joint...660
      FLYWHEEL...660
        Removing The Flywheel...660
        Installing The Flywheel...660
      MUFFLER...660
        Removing The Muffler...660
      RADIATOR...661
        Removing The Radiator...661
        Installing The Radiator...662
      BLOWER HOUSING...663
        Removing The Blower Housing...663
        Installing The Blower Housing...663
      STARTER...664
        Removing The Starter...664
        Installing The Starter...664
  TECHNICAL DATA...665
    TECHNICAL DATA (641 DEUTZ)...667
      641 LOADER SPECIFICATIONS...669
      OPERATION & PERFORMANCE SPECIFICATIONS...669
      ENGINE SPECIFICATIONS...669
      HYDRAULIC SYSTEM...670
      HYDRAULIC CYLINDERS...670
      HYDROSTATIC TRANSMISSION & FINAL DRIVE...670
      ELECTRICAL...670
      TIRES...670
      FLUID CAPACITIES...670
      ENGINE SPECIFICATIONS, 641 (Deutz – F2L511)...671
        Fuel System...671
        Governor, Front Cover And Throttle...671
        Cylinder Head And Valves...671
        Cylinder, Piston And Connecting Rod...671
        Camshaft, Crankshaft, Bearings...672
        Lubrication System...672
        Torque Specifications (Deutz Engine)...673
    TECHNICAL DATA (642 FORD)...675
      642 LOADER SPECIFICATIONS...677
      OPERATION & PERFORMANCE...677
      ENGINE SPECIFICATIONS...677
      HYDRAULIC SYSTEM...677
      HYDRAULIC CYLINDERS...678
      HYDROSTATIC TRANSMISSION & FINAL DRIVE...678
      ELECTRICAL...678
      TIRES...678
      FLUID CAPACITIES...678
      ENGINE SPECIFICATIONS, 642 (Ford)...679
        Fuel Specifications...679
        Engine Oil...679
        Lubrication System...680
        Cylinder Heads...680
        Valve Mechanism...680
        Camshaft...681
        Crankshaft...681
        Connecting Rod...681
        Piston...681
        Piston Pin...681
        Piston Rings...682
        Cylinder Block...682
        Ignition system...682
        Starter...682
        Torque Specifications For Engine...683
    TECHNICAL DATA (643 KUBOTA)...685
      643 LOADER SPECIFICATIONS...687
      OPERATION & PERFORMANCE...687
      ENGINE SPECIFICATIONS...687
      HYDRAULIC SYSTEM...687
      HYDROSTATIC TRANSMISSION & FINAL DRIVE...688
      ELECTRICAL...688
      TIRES...688
      FLUID CAPACITIES...688
      ENGINE SPECIFICATIONS...689
        Fuel Injection Nozzles...689
        Fuel Injection Pump...689
        Cylinder Head...689
        Valves...689
        Valve Springs...689
        Rocker Arms...689
        Camshaft...689
        Cylinder...690
        Piston Rings...690
        Pistons...690
        Crankshaft...690
        Oil Pump...690
        Engine Oil...690
      ENGINE BOLT TORQUES...691
    TECHNICAL DATA...693
      TORQUE SPECIFICATIONS...695
        Engine Group (641)...695
        Engine Group (642)...696
        Engine Group (643)...698
        Mainframe Group (All 640 Series)...700
        Seat Bar, Fuel Tank & Panel Group...701
        Steering Levers, Linkage Pedal Group (640 Series)...702
        Brake, Axle And Chaincase Group (640 Series)...703
        Hydraulic/Hydrostatic Group (640 Series)...704
      HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...705
        Hydraulic/Hydrostatic Fluid...705
      DECIMAL AND MILLIMETER EQUIVALENTS...706
      U.S. TO METRIC CONVERSION...706
      STANDARD TORQUE SPECIFICATIONS FOR BOLTS...707
  SERVICE BULLETINS...709
    640-001...709
    640-002...711
  SERVICE MANUAL REVISIONS...709
    640-3...713
    640-4...715
    640–5...717
    640–6...719
    640–7...721
    640–8...723
    640–9...725
    640–10...727
    640–11...729
    640–12...731
    640–13...733
    640–14...735
    640–15...737
    640–16...739
    640–17...741
    640–18...743
    640–19...745
    640–20...747
6566135 (6-12) - 641, 642, 643 Service Manual...749
  MAINTENANCE SAFETY...751
  SAFETY INSTRUCTIONS...753
    SAFETY IS YOUR RESPONSIBILITY...753
    BEFORE YOU WORK ON THE BOBCAT LOADER...753
  CONTENTS...755
    FOREWORD...755
  PREVENTIVE MAINTENANCE...757
    INTRODUCTION...759
      Serial Number Identification...759
      Loader Serial Number...759
      Engine Serial Number...759
    SERVICE SCHEDULE...761
    ENGINE SERVICE (General)...762
      Opening And Adjusting The Rear Door...762
      Engine Lubrication System...762
      Replacement Of Engine Oil And Filter...763
      Air Cleaner Service...765
    FUEL SYSTEM...766
      Fuel Filter (641)...766
      Fuel Filter (642)...767
      Fuel Filter (643)...767
      Removing Air From The Fuel System (641)...767
      Removing Air From The Fuel System (643)...768
    ENGINE COOLING SYSTEMS...768
      Removing Coolant From The Cooling System...769
    DRIVE BELTS...770
    ELECTRICAL SYSTEM SERVICE ...771
      Using An Extra Battery...771
      Installing A New Battery...772
    HYDRAULIC/HYDROSTATIC SYSTEM...773
    HYDRAULIC/HYDROSTATIC OIL RESERVOIR...773
      Checking And Adding Oil...773
      Removing Hydraulic Oil...774
      Replacement Of The Hydraulic Filter...775
    FINAL DRIVE TRANSMISSION (CHAINCASE)...775
    TIRE MAINTENANCE...775
      Tire Rotation...776
    LUBRICATION OF THE BOBCAT LOADER...776
    OPERATOR GUARD...777
    BOB–TACH...777
    PIVOT PINS...778
    AUXILIARY CONTROL LOCKBOLT...778
    LIFT ARM STOP...778
    SPARK ARRESTOR MUFFLER...779
  HYDRAULIC SYSTEM...781
    HYDRAULIC / HYDROSTATIC SCHEMATICS...783
    TROUBLESHOOTING...807
    HYDRAULIC SYSTEM INFORMATION...808
      37° Flare Connections...808
       Straight Thread O–Ring Fitting...808
      Tubelines And Hoses...808
    HYDRAULIC CONTROL VALVE (Victor)...809
       Relief Valve...809
      Checking The Relief Valve...809
      Removal Of The Relief Valve...810
      Installation Of The Relief Valve...810
      Removal Of The Control Valve...810
       Disassembly Of The Control Valve (Victor)...811
      Assembly And Inspection Of The Control Valve...813
    HYDRAULIC CONTROL VALVE (Melroe)...814
      Relief Valve...814
      Installing A New Relief Valve...814
      Disassembling The Control Valve...814
      Inspecting The Control Valve...817
      Assembling The Control Valve...817
    HYDRAULIC PUMP...820
      Checking Output Of The Hydraulic Pump...820
      Removing The Hydraulic Pump...820
      Checking The Hydraulic Pump...823
      Removing And Checking The Pump Shaft...823
      Installing The Hydraulic Pump...823
      Starting Procedure For The Hydraulic Pump...824
    LIFT CYLINDERS...824
      Checking The Lift Cylinders...824
      Removing The Lift Cylinder...825
      Disassembly Of The Cylinder...826
      Assembly Of The Lift Cylinder...827
      Installation Of The Lift Cylinder(s)...829
    TILT CYLINDER...830
      Checking The Tilt Cylinder...830
      Removing The Tilt Cylinder...830
      Disassembly Of The Tilt Cylinder...831
      Installation Of The Tilt Cylinder...832
    HYDRAULIC/HYDROSTATIC RESERVOIR...832
      Removing The Hydraulic/Hydrostatic Reservoir...832
      Installing The Hydraulic/Hydrostatic Reservoir...832
    OIL COOLER...833
      Removing The Oil Cooler On The 641...833
      Removing The Oil Cooler From The 642 & 643...833
      Installing The Oil Cooler...833
    10 MICRON FILTER BY–PASS VALVE...834
      Removing By–Pass Valve...834
      Installation Of The By–Pass Valve...834
    CONTROL PEDAL, LINKAGE AND LOCKS...834
      Removing Hydraulic Control Pedal...834
      Installing The Hydraulic Control Pedal...835
      Adjusting The Hydraulic Control Pedal...835
      Pedal Lock Linkage...836
  HYDROSTATIC SYSTEM...837
    TROUBLESHOOTING...839
    HYDROSTATIC SYSTEM INFORMATION...840
      Function Of High Pressure Relief Replenishing Valves...840
    STEERING LEVERS...841
      Removing The Steering Levers...841
      Repairing The Steering Levers...842
      Installing The Steering Levers...842
    STEERING LINKAGE...843
      Adjustment Of The Steering Linkage...843
      Removing The Steering Linkage...845
      Repairing The Pintle Lever...845
      Installing The Steering Linkage...846
    PORT BLOCK...846
      40 Micron Filter...846
      Cold Weather By–Pass Valve...847
      Neutral By–Pass Valve...848
      Removing The Port Block...849
      Installing The Port Block...849
    HYDROSTATIC MOTOR...850
      Removing The Hydrostatic Motor (Model 109–1174–006 & Above)...850
      Removing The Hydrostatic Motor (Model 109–1052–006 & Below)...850
      Disassembly Of The Hydrostatic Motor...851
      Hydrostatic Motor Inspection...856
      Assembly Of The Hydrostatic Motor ...857
      Installing The Hydrostatic Motor (Model 109–1173–006 & Above) (Splined Shaft)...862
      Installing the Hydrostatic Motor (Model 109–1052–006 & Below)...862
      Start–Up Procedure For The Hydrostatic Motor...863
    HYDROSTATIC PUMP...863
      Checking The High Pressure Relief Replenishing Valves...863
      Removing The Hydrostatic Pumps...865
      Disassembly Of The Hydrostatic Pump...867
      Hydrostatic Pump Inspection...870
      Assembly Of The Hydrostatic Pump...872
      Installing Pumps To Manifold Block...878
      Installing Hydrostatic Pump Assembly...880
    TOWING THE BOBCAT LOADER...880
  DRIVE SYSTEM...881
    BRAKES...883
      Brake Adjustment...883
      Brake Removal...884
    FINAL DRIVE...886
      Chain Replacement...886
    AXLES AND BEARINGS...887
      Axle And Bearing Removal...887
      Assembly Of The Axles...889
      Installing The Axles...889
    CHAINCASE FLUID...890
      Replacing The Chaincase Fluid...890
  MAIN FRAME...891
    RAISING AND LOWERING THE OPERATOR GUARD...893
      Raising The Operator Guard...893
      Lowering The Operator Guard...893
      Jumper Start Switch...894
    OPERATOR GUARD REMOVAL AND INSTALLATION...894
      Removing The Operator Guard...894
      Operator Guard Installation...895
    BOB–TACH FRAME (40 Series)...895
      Removing The Bob–Tach...895
      Disassembly Of The Bob–Tach...896
      Assembly Of The Bob–Tach...897
      Installing The Bob–Tach...899
    LIFT ARMS...900
      Removing The Lift Arms...900
      Installing The Lift Arms...901
    REAR DOOR...902
      Removing The Rear Door...902
      Installing The Rear Door...902
      Adjusting The Rear Door Latch...902
    FUEL TANK...903
      Removing The Fuel Tank...903
      Installing The Fuel Tank...903
    BOB–TACH (50 Series)...904
      Removal And Installation...904
      Bob–Tach Lever And Wedge...907
  ELECTRICAL SYSTEM...909
    ELECTRICAL SCHEMATICS...912
    TROUBLESHOOTING...935
    ELECTRICAL SYSTEM INFORMATION...936
      Electrical Circuitry...936
      Safety Procedures For The Battery...936
      Alternator Damage...937
    BATTERIES...937
      Checking The Battery...937
    WIRE HARNESS FOR THE OPERATOR GUARD...937
      Removing The Wire Harness For The Operator Guard...937
      Installing The Wire Harness For The Operator Guard...938
    WIRE HARNESS FOR THE ENGINE...939
      Removing The Wire Harness For The Engine...939
      Installing The Wire Harness For The Engine...939
    ALTERNATOR...939
      Checking The Alternator...939
      Removing The Alternator...940
      Repairing The Alternator...941
      Installing The Alternator...943
    STARTER...943
      Checking The Starter...943
      Removing The Starter...944
      Repairing The Starter...944
  ENGINE SERVICE...947
    ENGINE SERVICE (641 DEUTZ)...949
      TROUBLESHOOTING...951
      FUEL SYSTEM...952
        Fuel System Service...952
        Venting Air From The Fuel System...952
        Fuel Filters...953
        Fuel Water Trap...953
        Fuel Lift Pump...954
        Fuel Injection Pump...954
        Removal Of The Injection Pump...954
        Injection Pump Service...954
        Installing The Injection Pump...954
        Checking Adjustment Of Fuel Delivery...956
      FUEL INJECTION NOZZLES...957
        Removal...957
        Disassembly And Repair Of Injector (In The Shop)...957
        Installation Of The Injector...957
      BLOWER FAN...958
        Removal Of The Blower Fan...958
        Disassembly Of The Blower Fan...958
        Assembly Of The Blower Fan...958
        Installation Of The Blower Fan...959
      ENGINE SERVICE...959
      ENGINE REMOVAL...959
      CYLINDER HEAD AND VALVES...962
        Removal And Disassembly...962
        Repair And Assembly...962
        Checking Piston Crown Clearance And Installation Of Cylinder Head...964
      CYLINDER, PISTONS AND CONNECTING RODS...965
        Assembly...966
      OIL PUMP, FILTER HOUSING AND RELIEF VALVE...967
        Oil Pump Removal...967
        Installation...967
        Oil Pressure Relief Valve...967
      ENGINE FRONT COVER...967
        Removal...967
        Disassembly And Inspection...968
        Assembly...968
        Installation...969
      GOVERNOR...970
        Removal And Disassembly...970
        Assembly And Installation...970
      CAMSHAFT...971
        Removal...971
        Installation...971
        Crankshaft Removal...971
        Inspection...972
        Assembly...972
      UNIVERSAL JOINT...973
        Universal Joint Removal...973
        Universal Joint Installation...973
      FLYWHEEL...973
        Flywheel Removal...973
        Flywheel Installation...973
        Removing The Ring Gear...974
      ENGINE OIL COOLER...974
      ENGINE SHROUDING...974
      ENGINE MOUNTS...974
        Replacing Engine Mounts...974
      MUFFLER...975
        Removal Of The Muffler...975
      STARTER...975
        Starter Removal...975
    ENGINE SERVICE (642 FORD)...977
      TROUBLESHOOTING...979
      CHECKS AND ADJUSTMENTS...980
        Oil Pressure...980
        Valve Clearance...980
        Compression...980
        Carburetor, Throttle And Governor Adjustments...981
        Ignition System...983
          Spark Plug Wires Resistance Test...983
          Spark Plug Test...983
          Distributor Tests...983
          Dwell Angle Check...984
          Spark Strength Tests...984
          Battery To Coil Voltmeter Test...984
          Starting Ignition Circuit Voltmeter Test...985
          Breaker Point Gap Adjustment...985
        Ignition Timing...985
      CARBURETOR REPAIR...986
      ENGINE DIAGNOSIS AND TESTING...986
        Camshaft Lobe Lift...986
        Crankshaft End Play...987
        Flywheel Surface Alignment Check...987
        Camshaft End Play...988
      ENGINE REMOVAL...988
      ENGINE REPAIR...990
        Valve Guides...990
        Grinding The Valve Seats...990
        Valves...991
        Grinding Valves...991
        Select Fitting Of The Valves...991
        Camshaft Repair...991
        Crankshaft...991
        Repairing Journals...991
        To Check Crankshaft Or Connection Rod Bearings With Plastigage...991
        Installing Pistons...992
        Installing Piston Rings...993
        Installing The Piston Pins...993
        Valve Rocker Arm And Shaft Assembly...993
        Push Rods...993
      CYLINDER BLOCK...993
        Finishing The Cylinder Walls...993
      CYLINDER HEADS...994
        Cleaning The Cylinder Heads...994
        Checking The Cylinder Heads...994
      TAPPETS...994
        Cleaning The Tappets...994
        Checking The Tappets...995
      CAMSHAFT...995
        Cleaning And Checking The Camshaft...995
      CRANKSHAFT...995
        Checking The Crankshaft...995
      FLYWHEEL...995
        Checking The Flywheel...995
      CONNECTING RODS...995
        Cleaning The Connecting Rods...995
        Checking The Connecting Rods...995
      PISTONS, PINS AND RINGS...996
        Cleaning The Pistons, Pins and Rings...996
        Checking The Pistons, Pins And Rings...996
      MAIN BEARING AND CONNECTING ROD BEARINGS...996
        Cleaning Bearings...996
        Checking Bearings...996
      CYLINDER BLOCK...996
        Cleaning The Cylinder Block...996
        Checking The Cylinder...997
      OIL PUMP...997
        Cleaning The Oil Pump...997
        Checking The Oil Pump...997
      VALVE ROCKER ARM COVER AND ROCKER ARM SHAFT...998
        Removing And Disassembly Of The Rocker Arm Shaft...998
        Installing Rocker Arm Shaft...998
      VALVE PUSHRODS...999
        Removing The Valve Pushrods...999
        Installing The Valve Pushrods...999
      INTAKE MANIFOLD...999
        Removing The Intake Manifold...999
        Installing The Intake Manifold...999
      CYLINDER HEAD...1000
        Removing The Cylinder Head...1000
        Installing The Cylinder Head...1000
      VALVE SPRING, RETAINER AND STEM SEAL (With The Cylinder Head Removed)...1001
        Removing The Valve Spring...1001
        Installing The Valve Spring...1001
      VALVE SPRING, RETAINER AND STEM SEAL (With The Cylinder Head Installed)...1001
        Installing The Valve Spring...1002
      WATER PUMP...1003
        Removing The Water Pump...1003
      CYLINDER FRONT COVER, TIMING CHAIN AND CRANKSHAFT SPROCKETS...1003
        Removal...1003
        Removing The Timing Cover...1003
        Installation Of The Timing Cover...1004
      FRONT OIL SEAL...1004
        Removing The Front Oil Seal...1004
      FRONT OIL SEAL...1005
        Removing The Oil Seal...1005
        Installing The Oil Seal...1005
      TIMING CHAIN TIGHTENING...1005
        Removing The Chain Tightener...1005
        Installing The Chain Tightener...1005
      CAMSHAFT AND VALVE LIFTERS...1005
        Removing The Camshaft And Valve Lifters...1005
        Installing The Camshaft And Valve Lifters...1006
      OIL PAN...1007
        Removing The Oil Pan...1007
        Installing The Oil Pan...1008
      OIL PUMP...1008
        Removing The Oil Pump...1008
        Installing The Oil Pump...1008
      CRANKSHAFT REAR OIL SEAL...1008
        Removing The Rear Oil Seal...1008
        Installing The Rear Oil Seal...1009
      MAIN BEARINGS...1009
        Removing The Main Bearings...1009
        Installing The Main Bearings...1009
      CONNECTING ROD BEARINGS...1010
        Removing The Connecting Rod Bearings...1010
        Installing The Connecting Rod Bearings...1010
      PISTONS AND CONNECTING RODS...1010
        Removing The Pistons And Connecting Rods...1010
        Installing The Pistons And Connecting Rods...1011
      CAMSHAFT BEARINGS...1011
        Removing The Camshaft...1011
      CRANKSHAFT...1012
        Installing The Crankshaft...1012
      UNIVERSAL JOINT...1013
        Universal Joint Installation...1013
      FLYWHEEL...1013
        Flywheel Removal...1013
      FLYWHEEL RING GEAR...1014
        Removing The Ring Gear...1014
        Installing The Ring Gear...1014
      MUFFLER...1014
        Removing The Muffler...1014
      RADIATOR...1014
        Removing The Radiator...1014
        Installing The Radiator...1016
      BLOWER HOUSING...1016
        Removing The Blower Housing...1016
        Installing The Blower Housing...1017
      STARTER...1017
        Removing The Starter...1017
        Installing The Starter...1017
    ENGINE SERVICE (643 KUBOTA)...1019
      TROUBLESHOOTING...1021
      FUEL SYSTEM...1022
        Replacing The Fuel Filter...1022
        To Remove The Air From The Fuel System...1022
        Checking Glow Plugs...1022
        Removal And Installation Of The Fuel Injection Pump...1023
        Timing The Fuel System...1024
        Fuel Injector Nozzles...1024
      REMOVING AND INSTALLING THE ENGINE...1025
        Removing The Engine...1025
        Installing The Engine...1027
      REPAIRING THE CYLINDER HEAD...1028
        Removing The Cylinder Head...1028
        Disassembly Of The Cylinder Head...1029
        Servicing The Cylinder Head...1029
        Assembly Of The Cylinder Head...1031
        Installing The Cylinder Head...1031
        Adjusting The Compression Release Mechanism (S/N 11620 and Below Only)...1032
      REPAIRING THE ENGINE...1033
        Removing The Gear Case...1033
        Removing The Timing Gear, Camshaft And Oil Pump...1034
        Removing Pistons And Crankshaft...1035
        Servicing The Timing Gear And Camshaft...1036
        Servicing The Connecting Rods And Pistons...1037
        Servicing The Crankshaft...1038
        Servicing The Cylinder Liners...1039
        Servicing The Oil Pump...1040
        Servicing The Water Pump...1041
      ASSEMBLY OF THE ENGINE...1041
        Installing The Crankshaft...1041
        Installing Pistons...1042
        Installing The Camshaft And Timing Gears...1042
        Installing The Gear Case Cover...1043
      UNIVERSAL JOINT...1044
        Removing The U–Joint...1044
        Installing The U–Joint...1044
      FLYWHEEL...1044
        Removing The Flywheel...1044
        Installing The Flywheel...1044
      MUFFLER...1044
        Removing The Muffler...1044
      RADIATOR...1045
        Removing The Radiator...1045
        Installing The Radiator...1046
      BLOWER HOUSING...1047
        Removing The Blower Housing...1047
        Installing The Blower Housing...1047
      STARTER...1048
        Removing The Starter...1048
        Installing The Starter...1048
  TECHNICAL DATA...1049
    TECHNICAL DATA (641 DEUTZ)...1051
      641 LOADER SPECIFICATIONS...1053
      OPERATION & PERFORMANCE SPECIFICATIONS...1053
      ENGINE SPECIFICATIONS...1053
      HYDRAULIC SYSTEM...1054
      HYDRAULIC CYLINDERS...1054
      HYDROSTATIC TRANSMISSION & FINAL DRIVE...1054
      ELECTRICAL...1054
      TIRES...1054
      FLUID CAPACITIES...1054
      ENGINE SPECIFICATIONS, 641 (Deutz – F2L511)...1055
        Fuel System...1055
        Governor, Front Cover And Throttle...1055
        Cylinder Head And Valves...1055
        Cylinder, Piston And Connecting Rod...1055
        Camshaft, Crankshaft, Bearings...1056
        Lubrication System...1056
        Torque Specifications (Deutz Engine)...1057
    TECHNICAL DATA (642 FORD)...1059
      642 LOADER SPECIFICATIONS...1061
      OPERATION & PERFORMANCE...1061
      ENGINE SPECIFICATIONS...1061
      HYDRAULIC SYSTEM...1061
      HYDRAULIC CYLINDERS...1062
      HYDROSTATIC TRANSMISSION & FINAL DRIVE...1062
      ELECTRICAL...1062
      TIRES...1062
      FLUID CAPACITIES...1062
      ENGINE SPECIFICATIONS, 642 (Ford)...1063
        Fuel Specifications...1063
        Engine Oil...1063
        Lubrication System...1064
        Cylinder Heads...1064
        Valve Mechanism...1064
        Camshaft...1065
        Crankshaft...1065
        Connecting Rod...1065
        Piston...1065
        Piston Pin...1065
        Piston Rings...1066
        Cylinder Block...1066
        Ignition system...1066
        Starter...1066
        Torque Specifications For Engine...1067
    TECHNICAL DATA (643 KUBOTA)...1069
      643 LOADER SPECIFICATIONS...1071
      OPERATION & PERFORMANCE...1071
      ENGINE SPECIFICATIONS...1071
      HYDRAULIC SYSTEM...1071
      HYDROSTATIC TRANSMISSION & FINAL DRIVE...1072
      ELECTRICAL...1072
      TIRES...1072
      FLUID CAPACITIES...1072
      ENGINE SPECIFICATIONS...1073
        Fuel Injection Nozzles...1073
        Fuel Injection Pump...1073
        Cylinder Head...1073
        Valves...1073
        Valve Springs...1073
        Rocker Arms...1073
        Camshaft...1073
        Cylinder...1074
        Piston Rings...1074
        Pistons...1074
        Crankshaft...1074
        Oil Pump...1074
        Engine Oil...1074
      ENGINE BOLT TORQUES...1075
    TECHNICAL DATA...1077
      TORQUE SPECIFICATIONS...1079
        Engine Group (641)...1079
        Engine Group (642)...1080
        Engine Group (643)...1082
        Mainframe Group (All 640 Series)...1084
        Seat Bar, Fuel Tank & Panel Group...1085
        Steering Levers, Linkage Pedal Group (640 Series)...1086
        Brake, Axle And Chaincase Group (640 Series)...1087
        Hydraulic/Hydrostatic Group (640 Series)...1088
      HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...1089
        Hydraulic/Hydrostatic Fluid...1089
      DECIMAL AND MILLIMETER EQUIVALENTS...1090
      U.S. TO METRIC CONVERSION...1090
      STANDARD TORQUE SPECIFICATIONS FOR BOLTS...1091
  SERVICE BULLETINS...1093
    640-001...1093
    640-002...1095
  SERVICE MANUAL REVISIONS...1093
    640-3...1097
    640-4...1099
    640–5...1101
    640–6...1103
    640–7...1105
    640–8...1107
    640–9...1109
    640–10...1111
    640–11...1113
    640–12...1115
    640–13...1117
    640–14...1119
    640–15...1121
    640–16...1123
    640–17...1125
    640–18...1127
    640–19...1129
    640–20...1131
    640-21...1133
6566557 (4-83) - 643 Operator's Manual...1135
  WARNINGS...1137
  FOREWORD...1139
    CONTENTS...1139
    REFERNCE INFORMATION...1139
    SAFETY INSTRUCTIONS...1141
    643 BOBCAT LOADER IDENTIFICATION...1142
  OPERATING INSTRUCTIONS...1143
    OPERATING INSTRUCTIONS...1145
    CONTROLS...1146
    DECAL LOCATIONS...1147
    DASH PANEL...1148
    THROTTLE CONTROL...1148
    STOPPING THE ENGINE...1148
    PARKING BRAKE...1148
    STEERING LEVERS...1149
    HYDRAULIC CONTROLS...1150
      Foot Pedals (Hydraulic)...1150
    BEFORE YOU START THE ENGINE...1151
    STARTING THE ENGINE...1152
      Normal Starting Condition...1153
      Cold Temperature Starting Condition...1153
    BOBCAT LOADER OPERATION...1154
      Bucket Size...1154
      Installation Of Attachments...1155
      Removal Of Attachments...1155
    OPERATING PROCEDURE...1156
      Filling The Bucket...1157
      To Empty The Bucket...1157
      Digging Into The Ground...1158
      Making The Ground Level Using Float Position...1158
      Filling A Hole...1158
    STOPPING THE BOBCAT LOADER...1159
    TRANSPORTING THE BOBCAT LOADER...1159
    LIDT ARM STOP...1160
    LIFTING THE OPERATOR GUARD...1160
    LOWERING THE OPERATOR GUARD...1161
  PREVENTIVE MAINTENANCE...1163
    WARNINGS...1164
    SERVICE SCHEDULE...1165
    ENGINE SERVICE...1166
    ADJUSTING DOOR LATCH...1166
    AIR CLEANER SERVICE...1166
    FUEL SYSTEM...1167
    FUEL SYSTEM SERVICE...1167
    FUEL FILTER...1167
    REMOVING AIR FROM THE FUEL SYSTEM...1168
    ENGINE LUBRICATION SYSTEM...1168
    REPLACEMENT OF ENGINE OIL AND FILTER...1169
    COOLANT LEVEL...1169
    REMOVING COOLANT FROM THE COOLING SYSTEM...1170
    ALTERNATOR BELT...1170
    ELECTRICAL SYSTEM...1170
    USING AN EXTRA BATTERY (JUMP STARTING)...1173
    TO INSTALL A NEW BATTERY...1174
    SPARK ARRESTOR MUFFLER...1175
    HYDRAULIC SYSTEM...1175
    HYDRAULIC/HYDROSTATIC OIL RESERVOIR...1175
      Checking And Adding Oil...1177
      Removing Hydraulic Oil...1177
    REPLACEMENT OF THE HYDRAULIC FILTER...1178
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1178
    TIRE MAINTENANCE...1178
      Tire Rotation...1179
      Wheel Nuts...1179
    LUBRICATION OF THE BOBCAT LOADER...1179
    ROLL OVER & FALLING OBJECT PROTECTION STRUCTURE (ROPS & FOPS)...1180
    BOB-TACH...1180
    PIVOT PINS...1181
    BRAKE PEDAL ADJUSTMENT...1181
    DELIVERY REPORT...1182
  TROUBLESHOOTING...1183
    TROUBLESHOOTING THE ENGINE...1184
    TROUBLESHOOTING THE DRIVE SYSTEM...1185
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...1186
  MAJOR PARTS...1187
    MAIN FRAME...1188
    SEAT & PANELS...1189
    DRIVE SYSTEM...1190
    BRAKES...1191
    CONTROL PEDALS...1192
    HYDRAULIC SYSTEM...1193
    HYDROSTATIC SYSTEM...1194
    HAND CONTROLS...1195
    OPERATOR CAB ELECTRICAL SYSTEM...1196
    ENGINE ELECTRICAL SYSTEM...1197
    ENGINE & ATTACHING PARTS...1198
    DECALS...1200
  DECALS...1201
    WARNING  - 6563484...1202
    SERVICE SCHEDULE - 6566318...1203
    WARNING - 6561380...1205
    WARNING - 6563380...1206
    IMPORTANT - 6560573...1207
  GENERAL INFORMATION...1209
    643 LOADER SPECIFICATIONS...1211
    OPERATION & PERFORMANCE...1211
    ENGINE...1211
    LOADER HYDRAULICS...1211
    ELECTRICAL...1212
    DRIVE SYSTEM...1212
    CAPACITIES...1212
    TIRES...1212
    ADDITIONAL PUBLICATIONS...1213
  WARRANTY...1214
6566561 (2-83) - 641 Operator's Manual...1216
  WARNINGS...1217
  SAFETY INSTRUCTIONS...1218
  FOREWORD...1220
    CONTENTS...1220
    641 BOBCAT LOADER IDENTIFICATION...1221
  OPERATING INSTRUCTIONS...1222
    OPERATING INSTRUCTIONS...1224
    CONTROLS...1225
    DECAL LOCATIONS...1226
    DASH PANEL...1227
    THROTTLE CONTROL...1227
    STOPPING THE ENGINE...1227
    PARKING BRAKE...1227
    STEERING LEVERS...1228
    HYDRAULIC CONTROLS...1229
      Foot Pedals (Hydraulic)...1229
      Lift Arm Operation...1229
      Float Position...1229
      Tilt (Bucket) Operation...1229
      Auxiliary lever...1230
    BEFORE YOU START THE ENGINE...1230
    STARTING THE ENGINE...1231
      Normal Starting Condition...1232
      Easier Starting In Cold Temperature...1232
      Cold Temperature Starting...1233
    BOBCAT LOADER OPERATION...1233
      Bucket Size...1233
      Intsallation Of Attachments...1234
      Removal Of Attachments...1234
    OPERATING PROCEDURE...1235
      Filling The Bucket...1236
      To Empty The Bucket...1236
      Digging Into The Ground...1237
      MakingThe Ground Level Using Float Position...1237
      Filling A Hole...1237
    STOPPING THE BOBCAT LOADER...1238
    TRANSPORTING THE BOBCAT LOADER...1238
    LIFT ARM STOP...1239
    LIFTING THE OPERATOR GUARD...1240
    LOWERING THE OPERATOR GUARD...1240
  PREVENTIVE MAINTENANCE...1242
    WARNINGS...1243
    SERVICE SCHEDULE...1244
    ENGINE SERVICE...1245
    ADJUSTING DOOR LATCH...1245
    AIR CLEANER SERVICE...1245
    FUEL SYSTEM...1246
    FUEL SYSTEM SERVICE...1246
    FUEL FILTER...1246
    REMOVING AIR FROM THE FUEL SYSTEM...1247
    ENGINE LUBRICATION SYSTEM...1247
    REPLACEMENT OF ENGINE OIL AND FILTER...1248
    ENGINE COOLING SYSTEM...1248
    ALTERNATOR BELT...1249
    ELECTRICAL SYSTEM...1249
    USING AN EXTRA BATTERY (JUMP STARTING)...1252
    TO INSTALL A NEW BATTERY...1254
    SPARK ARRESTOR MUFFLER...1254
    HYDRAULIC SYSTEM...1255
    HYDRAULIC/HYDROSTATIC OIL RESERVOIR...1256
      Checking And Adding Oil...1256
      Removing Hydraulic Oil...1257
    REPLACEMENT OF THE HYDRAULIC FILTER...1257
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1257
    TO DRAIN CHAINCASE OIL...1258
    TIRE MAINTENANCE...1258
      Tire Rotation...1258
      Wheel Nuts...1258
    LUBRICATION OF THE BOBCAT LOADER...1259
    OPERATOR GUARD...1260
    BOB-TACH...1260
    PIVOT PINS...1261
    AUXILIARY CONTROL LOCKBOLT...1261
    BRAKE PEDAL ADJUSTMENT...1261
    DELIVERY REPORT...1262
  TROUBLESHOOTING...1264
    TROUBLESHOOTING THE ENGINE...1266
    TROUBLESHOOTING THE DRIVE SYSTEM...1267
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...1268
  MAJOR PARTS...1270
    MAIN FRAME...1272
    PANELS, SEAT, SEAT BAR & FUEL SYSTEM...1273
    DRIVE SYSTEM...1274
    HYDRAULIC SYSTEM...1275
    CONTROL PEDALS...1276
    HYDROSTATIC SYSTEM...1277
    HAND CONTROLS...1278
    OPERATOR GUARD ELECTRICAL SYSTEM...1279
    ENGINE ELECTRICAL SYSTEM...1280
    ENGINE & ATTACHING PARTS...1281
    DECALS...1283
  DECALS...1284
    WARNING - 6563484...1286
    SERVICE SCHEDULE - 6565318...1287
    WARNING - 6561380...1289
    WARNING - 6563380...1290
    IMPORTANT - 6560573...1291
  SPECIFICATIONS...1293
    LOADER SPECIFICATIONS...1293
    OPERATION & PERFORMANCE...1293
    ENGINE...1293
    HYDRAULIC SYSTEM...1294
    HYDRAULIC CYLINDERS...1294
    HYDROSTATIC TRANSMISSION & FINAL DRIVE...1294
    ELECTRICAL...1294
    TIRES...1294
    FLUID CAPACITIES...1294
    ADDITIONAL PUBLICATIONS...1295
  WARRANTY...1297
6566562 (2-83) - 642 Operator's Manual...1299
  WARNINGS...1300
  SAFETY INSTRUCTIONS...1301
  FOREWORD...1303
    CONTENTS...1303
    REFERENCE INFORMATION...1303
    642 BOBCAT LOADER IDENTIFICATION...1304
  OPERATING INSTRUCTIONS...1305
    OPERATING INSTRUCTIONS...1307
    CONTROLS...1308
    SAFETY SIGNS (DECALS)...1309
    DASH PANEL...1310
    THROTTLE CONTROL...1310
    CHOKE CONTROL...1310
    STOPPING THE ENGINE...1310
    PARKING BRAKE...1310
    STEERING LEVERS...1311
    HYDRAULIC CONTROLS...1312
      Foot Pedal (Hydraulic)...1312
      Lift Arm Operation...1312
      Float Position...1312
      Tilt (Bucket) Operation...1312
      Auxiliary Lever...1313
    BEFORE YOU START THE ENGINE...1313
    STARTING THE ENGINE...1314
      Normal Starting Condition...1315
      Cold Temperature Starting Condition...1315
    BOBCAT LOADER OPERATION...1316
      Bucket Size...1316
      Installation Of Attachments...1317
      Removal Of Attachments...1317
    OPERATING PROCEDURE...1318
      Filling The Bucket...1319
      To Empty The Bucket...1319
      Digging Into The Ground...1320
      MakingThe Ground Level Using Float Position...1320
      Filling A Hole...1320
    STOPPING THE BOBCAT LOADER...1321
    TRANSPORTING THE BOBCAT LOADER...1321
    LIFT ARM STOP...1322
    LIFTING THE OPERATOR GUARD...1323
    LOWERING THE OPERATOR GUARD...1323
  PREVENTIVE MAINTENANCE...1325
    WARNINGS...1326
    SERVICE SCHEDULE...1327
    ENGINE SERVICE...1328
    ADJUSTING THE DOOR LATCH...1328
    AIR CLEANER SERVICE...1328
    FUEL SYSTEM SERVICE...1329
    FUEL FILTER...1330
    ENGINE LUBRICATION SYSTEM...1330
    REPLACEMENT OF ENGINE OIL AND FILTER...1330
    COOLANT LEVEL...1331
    REMOVING COOLANT FROM THE COOLING SYSTEM...1332
    DRIVE BELTS...1332
    ELECTRICAL SYSTEM...1333
    USING AN EXTRA BATTERY (JUMP STARTING)...1336
    INSTALLING A NEW BATTERY...1337
    SPARK ARRESTOR MUFFLER...1338
    HYDRAULIC SYSTEM...1338
    HYDRAULIC/HYDROSTATIC OIL RESERVOIR...1338
      Checking And Adding Oil...1340
      Removing Hydraulic Oil...1340
    REPLACEMENT OF THE HYDRAULIC FILTER...1341
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1341
    TIRE MAINTENANCE...1341
      Tire Rotation...1342
    LUBRICATION OF THE BOBCAT LOADER...1342
    OPERATOR GUARD (ROPS & FOPS)...1343
    BOB-TACH...1344
    PIVOT PINS...1344
    AUXILIARY CONTROL LOCKBOLT...1344
    BRAKE PEDAL ADJUSTMENT...1344
    DELIVERY REPORT...1345
  TROUBLESHOOTING...1347
    TROUBLESHOOTING THE ENGINE...1349
    TROUBLESHOOTING THE DRIVE SYSTEM...1350
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...1351
  MAJOR PARTS...1353
    MAIN FRAME...1355
    PANELS, SEAT, SEAT BAR & FUEL SYSTEM...1356
    DRIVE SYSTEM...1357
    HYDRAULIC SYSTEM...1358
    HYDROSTATIC SYSTEM...1359
    HAND CONTROLS...1360
    OPERATOR GUARD ELECTRICAL SYSTEM...1361
    ENGINE ELECTRICAL SYSTEM...1362
    ENGINE & ATTACHING PARTS...1363
    DECALS...1365
  DECALS...1367
    WARNING - 6563484...1369
    SERVICE SCHEDULE - 6565318...1370
    WARNING - 6561380...1372
    WARNING - 6563380...1373
    IMPORTANT - 6560573...1374
  GENERAL INFORMATION...1375
    LOADER SPECIFICATIONS...1377
    OPERATION & PERFORMANCE...1377
    ENGINE...1377
    HYDRAULIC SYSTEM...1377
    HYDRAULIC CYLINDERS...1378
    HYDROSTATIC TRANSMISSION & FINAL DRIVE...1378
    ELECTRICAL...1378
    TIRES...1378
    FLUID CAPACITIES...1378
    ADDITIONAL PUBLICATIONS...1379
  WARRANTY...1381
6566706 (4-84) - 641 Operator's Manual...1383
  WARNINGS...1384
  FOREWORD...1385
    CONTENTS...1385
    REFERENCE INFORMATION...1385
    SAFETY INSTRUCTIONS...1387
    FIRE PREVENTIONS...1388
    SERIAL NUMBER LOCATIONS...1389
    DELIVERY REPORT...1389
    BOBCAT LOADER IDENTIFICATION...1390
  OPERATING INSTRUCTIONS...1391
    OPERATING INSTRUCTIONS...1393
    CONTROLS...1394
    SAFETY SIGNS (DECALS)...1395
    DASH PANEL...1397
    THROTTLE CONTROL...1397
    TO STOP THE ENGINE...1397
    PARKING BRAKE...1397
    STEERING LEVERS...1398
    HYDRAULIC CONTROLS...1399
      Foot Pedals (Hydraulic)...1399
      Lift Arm Operation...1399
      Floadt Position...1399
      Tilt (Bucket) Operation...1399
      Auxiliary Lever Operation...1399
    BEFORE YOU START THE ENGINE...1400
    STARTING THE ENGINE...1401
      Normal Starting Condition...1402
      Cold Temperature Starting Condition...1403
    ATTACHMENTS & BUCKETS...1403
      Installation Of Attachments...1404
      Installation Of Bucket...1404
      Removal Of Bucket...1405
    OPERATING PROCEDURE...1405
      Filling A Bucket...1406
      To Empty A Bucket...1406
      Digging Into The Ground...1407
      Making The Ground Level Using Float Position...1407
      Filling A Hole (Backfilling)...1408
    PARKING THE BOBCAT LOADER...1408
    TRANSPORTING THE BOBCAT LOADER...1408
    LIFTING THE BOBCAT LOADER...1409
  PREVENTIVE MAINTENANCE...1411
    WARNINGS...1412
    SERVICE SCHEDULE...1413
    LIFT ARM STOP...1414
    LIFTING THE OPERATOR CAB...1414
    LOWERING THE OPERATOR CAB...1415
    ROLLOVER & FALLING OBJECT PROTECTION STRUCTURE (ROPS & FOPS)...1415
    ENGINE SERVICE...1416
      Opening The Rear Door...1416
      Adjusting The Rear Door Latch...1416
    AIR CLEANER SERVICE...1416
    FUEL SYSTEM...1417
    FUEL SYSTEM SERVICE...1417
    FUEL FILTER...1418
    REMOVING AIR FROM THE FUEL SYSTEM...1418
    ENGINE LUBRICATION SYSTEM...1418
    REPLACEMENT OF ENGINE OIL AND FILTER...1419
    ENGINE COOLING SYSTEM...1420
    BELT ADJUSTMENT...1420
    ELECTRICAL SYSTEM...1420
    USING AN EXTRA BATTERY (JUMP STARTING)...1423
    INSTALLING A NEW BATTERY...1424
    SPARK ARRESTOR MUFFLER...1425
    HYDRAULIC / HYDROSTATIC SYSTEM...1426
    REPLACEMENT OF THE HYDRAULIC FILTER ELEMENT...1428
    HYDRAULIC / HYDROSTATIC FLUID RESERVOIR...1428
      Checking And Adding Fluid...1428
      Removing Thje Hydraulic Fluid...1428
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1429
    TIRE MAINTENANCE...1429
      Tire Rotation...1429
      Wheel Nuts...1430
    LUBRICATION OF THE BOBCAT LOADER...1430
    BOB-TACH...1431
    PIVOT PINS...1431
    BRAKE PEDAL ADJUSTMENT...1431
    AUXILIARY LOCKBOLT...1431
  TROUBLESHOOTING...1433
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...1435
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM...1436
    TROUBLESHOOTING THE ENGINE...1437
  MAJOR PARTS...1439
    MAIN FRAME...1441
    SEAT, PANELS & FUEL TANK...1442
    DRIVE SYSTEM...1443
    BRAKES...1444
    CONTROL PEDALS...1445
    HYDRAULIC SYSTEM...1446
    HAND CONTROLS...1447
    OPERATOR CAB ELECTRICAL SYSTEM...1448
    ENGINE ELECTRICAL SYSTEM...1449
    ENGINE & ATTACHING PARTS...1450
  WARNING SIGNS...1453
    WARNING - 6565980...1455
    SERVICESCHEDULE - 6567875...1456
    WARNING - 6563380...1458
    WARNING - 6561380...1459
    IMPORTANT - 6560573...1460
  GENERAL INFORMATION...1461
    641 LOADER SPECIFICATIONS...1463
    OPERATION & PERFORMANCE...1463
    ENGINE...1463
    LOADER HYDRAULICS...1464
    ELECTRICAL...1464
    DRIVE SYSTEM...1464
    CAPACITIES...1464
    TIRES...1464
    ADDITIONAL PUBLICATIONS...1465
  WARRANTY...1467
6566707 (3-84) - 642 Operator's Manual...1468
  WARNINGS...1470
  FOREWORD...1472
    CONTENTS...1472
    REFERENCE INFORMATION...1472
    SAFETY INSTRUCTIONS...1474
    FIRE PREVENTION...1475
    SERIAL NUMBER LOCATIONS...1476
    DELIVERY REPORT...1476
    642 BOBCAT LOADER IDENTIFICATION...1477
  OPERATING INSTRUCTIONS...1478
    OPERATING INSTRUCTIONS...1480
    CONTROLS...1481
    SAFETY SIGNS (DECALS)...1482
    DASH PANEL...1484
    THROTTLE CONTROL...1484
    CHOKE CONTROL...1484
    TO STOP THE ENGINE...1484
    PARKING BRAKE...1484
    STEERING LEVERS...1485
    HYDRAULIC CONTROLS...1486
      Foot Pedals (Hydraulic)...1486
      Lift Arm Operation...1486
      Float Position...1486
      Tilt (Bucket) Operation...1486
      Auxiliary Lever Operation...1486
    BEFORE YOU START THE ENGINE ...1487
    STARTING THE ENGINE...1488
      Normal Starting Condition...1489
      Cold Temperature Starting Condition...1490
    ATTACHMENT & BUCKETS...1490
      Installation Of Attachment...1491
      Installation Of Bucket...1491
      Removal Of Bucket...1492
    OPERATING PROCEDURE...1492
      Filling A Bucket...1493
      To Empty A Bucket...1493
      Digging Into The Ground...1494
      Making The Ground Level Using Float Position...1494
      Filling A Hole (Backfilling)...1495
    PARKING THE BOBCAT LOADER...1495
    TRANSPORTING THE BOBCAT LOADER...1495
    LIFTING THE BOBCAT LOADER...1496
  PREVENTIVE MAINTENANCE...1498
    WARNINGS...1499
    SERVICE SCHEDULE...1500
    LIFT ARM STOP...1501
    LIFTING THE OPERATOR CAB...1501
    LOWERING THE OPERATOR CAB...1502
    ROLLOVER & FALLING OBJECT PROTECTION STRUCTURE (ROPS & FOPS)...1502
    ENGINE SERVICE...1503
      Opening The Rear Door...1503
      Adjusting The Rear Door Latch...1503
    AIR CLEANER SERVICE...1503
    FUEL SYSTEM...1504
    FUEL SYSTEM SERVICE...1504
    FUEL FILTER...1505
    ENGINE LUBRICATION SYSTEM...1505
    REPLACEMENT OF ENGINE OIL AND FILTER...1506
    COOLANT LEVEL...1507
    REMOVING COOLANT FROM THE COOLING SYSTEM...1507
    BELT ADJUSTMENT...1507
    GOVENOR OIL LEVEL...1508
    ELECTRICAL SYSTEM...1508
    USING AN EXTRA BATTERY (JUMP STARTING)...1511
    INSTALLING A NEW BATTERY...1512
    SPARK ARRESTOR MUFFLER...1513
    HYDRAULIC/HYDROSTATIC SYSTEM...1514
    REPLACEMENT OF THE HYDRAULIC FILTER ELEMENT...1515
    HYDRAULIC/HYDROSTATIC FLUID RESERVOIR...1515
      Checking And Adding Fluid...1515
      Removing Hydraulic Fluid...1516
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1516
    TIRE MAINTENANCE...1516
      Tire Repair...1517
      Wheel Nuts...1517
    LUBRICATION OF THE BOBCAT LOADER...1517
    BOB-TACH...1518
    PIVOT PINS...1518
    BRAKE PEDAL ADJUSTMENT...1519
    AUXILIARY LOCKBOLT...1519
  TROUBLESHOOTING...1520
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...1522
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM...1523
    TROUBLESHOOTING THE ENGINE...1524
  MAJOR PARTS...1526
    MAIN FRAME...1528
    SEAT, PANELS & FUEL TANK...1529
    DRIVE SYSTEM...1530
    BRAKES...1531
    CONTROL PEDALS...1532
    HYDRAULIC SYSTEM...1533
    HAND CONTROLS...1534
    OPERATOR CAB ELECTRICAL SYSTEM...1535
    ENGINE ELECTRICAL SYSTEM...1536
    ENGINE & ATTACHING PARTS...1537
  WARNING SIGNS...1542
    WARNING - 6565980...1542
    SERVICE SCHEDULE - 6567875...1543
    WARNING -6563380...1545
    WARNING - 6561380...1546
    IMPORTANT - 6560573...1547
  GENERAL INFORMATION...1548
    642 LOADER SPECIFICATIONS...1550
    OPERATION & PERFORMANCE...1550
    ENGINE...1550
    LOADER HYDRAULICS...1551
    ELECTRICAL...1551
    DRIVE SYSTEM...1551
    CAPACITIES...1551
    TIRES...1551
    ADDITIONAL PUBLICATIONS...1552
  WARRANTY...1554
6566708 (10-98) - 643 Operation & Maintenance Manual...1556
  OPERATOR SAFETY WARNINGS...1558
  FOREWORD...1560
    CONTENTS...1560
    SAFETY INSTRUCTIONS...1562
      SAFETY IS YOUR RESPONSIBILITY...1562
      BEFORE YOU OPERATE THE BOBCAT LOADER...1562
      SAFE OPERATION NEEDS A QUALIFIED OPERATOR...1563
    FIRE PREVENTION...1563
    SERIAL NUMBER LOCATIONS...1564
    DELIVERY REPORT...1564
    BOBCT LOADER IDENTIFICATION...1565
  OPERATING INSTRUCTIONS...1566
    OPERATING INSTRUCTIONS...1568
    CONTROLS...1569
    SAFETY SIGNS (DECALS)...1570
    DASH PANEL...1572
    THROTTLE CONTROL...1572
    TO STOP THE ENGINE...1572
    PARKING BRAKE...1572
    STEERING LEVERS...1573
    HYDRAULIC CONTROLS...1574
      Foot Pedals (Hydraulic)...1574
      Lift Arm Operation...1574
      Float Position...1574
      Tilt (Bucket) Operation...1574
      Auxiliary Lever Operation...1574
    BEFORE YOU START THE ENGINE...1575
    STARTING THE ENGINE...1576
      Normal Starting Condition...1577
      Cold Temperature Starting Condition...1578
    ATTACHMENTS & BUCKETS...1578
      Installation Of Attachments...1579
      Installation Of Bucket...1579
      Removal Of Bucket...1580
    OPERATING PROCEDURE...1580
      Filling A Bucket...1581
      To Empty A Bucket...1581
      Digging Into The Ground...1582
      Making The Ground Level Using Float Postion...1582
      Filling A Hole...1583
    PARKING THE BOBCAT LOADER...1583
    TRANSPORTING THE BOBCAT LOADER...1583
    LIFTING THE BOBCAT LOADER...1584
  PREVENTIVE MAINTENANCE...1586
    WARNINGS...1588
    SERVICE SCHEDULE...1590
    LIFT ARM STOP...1591
    LIFTING THE OPERATOR CAB...1591
    LOWERING THE OPERATOR CAB...1592
    ROLLOVER & FALLING OBJECT PROTECTIVE STRUCTURE (ROPS & FOPS)...1592
    ENGINE SERVICE...1593
      Opening The Rear Door...1593
      Adjusting The Rear Door Latch...1593
    AIR CLEANER SERVICE...1593
    FUEL SYSTEM...1594
    FUEL SYSTEM SERVICE...1594
    FUEL FILTER...1595
    REMOVING AIR FROM THE FUEL SYSTEM...1595
    ENGINE LUBRICATION SYSTEM...1596
    REPLACEMENT OF ENGINE OIL AND FILTER...1596
    COOLANT LEVEL...1597
    REMOVING COOLANT FROM THE COOLING SYSTEM...1597
    BELT ADJUSTMENT...1598
    ELECTRICAL SYSTEM...1598
    USING AN EXTRA BATTERY (JUMP STARTING)...1601
    INSTALLING A NEW BATTERY...1602
    SPARK ARRESTOR MUFFLER...1603
    HYDRAULIC/HYDROSTATIC SYSTEM...1604
    REPLACEMENT OF THE HYDRAULIC FILTER ELEMENT...1605
    HYDRAULIC / HYDROSTATIC FLUID RESERVOIR...1605
      Checking And Adding Fluid...1605
      Removing The Hydraulic Fluid...1606
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1606
    TIRE MAINTENANCE...1606
      Tire Rotation...1607
      Wheel Nuts...1607
    LUBRICATION OF THE BOBCAT LOADER...1607
    BOB-TACH...1608
    PIVOT PINS...1608
    BRAKE PEDAL ADJUSTMENT...1609
    AUXILIARY LOCKBOLT...1609
  TROUBLESHOOTING...1610
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...1612
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM...1613
    TROUBLESHOOTING THE ENGINE...1614
  MAJOR PARTS...1616
    MAIN FRAME...1618
    SRAT, PANELS & FUEL SYSTEM...1619
    DRIVE SYSTEM...1620
    BRAKES...1621
    CONTROL PEDALS...1622
    HYDRAULIC SYSTEM...1623
    HAND CONTROLS...1624
    OPERATOR CAB ELECTRICAL SYSTEM...1625
    ENGINE ELECTRICAL SYSTEM...1626
    ENGINE & ATTACHING PARTS...1627
  WARNING SIGNS...1630
    WARNING - 6565980...1632
    SERVICE SCHEDULE - 6567875...1633
    WARNING - 6563380...1635
    WARNING - 6561380...1636
    IMPORTANT - 6560573...1637
  GENERAL INFORMATION...1638
    643 LOADER SPECIFICATIONS...1640
    OPERATION & PERFORMANCE...1640
    ENGINE...1640
    LOADER HYDRAULICS...1641
    ELECTRICAL...1641
    DRIVE SYSTEM...1641
    CAPACITIES...1641
    TIRES...1641
    ADDITIONAL PUBLICATIONS...1642
  WARRANTY...1644
6570246 (4-87) - 642B Operator's Manual...1646
  OPERATOR SAFETY WARNINGS...1647
  FOREWORD...1648
    CONTENTS...1648
    REFERENCE INFORMATION...1648
    SAFETY INSTRUCTIONS...1650
    FIRE PREVENTION...1651
    SERIAL NUMBER LOCATIONS...1652
    DELIVERY REPORT...1652
    BOBCAT LOADER IDENTIFICATION...1653
  OPERATING INSTRUCTIONS...1654
    OPERATING INSTRUCTIONS...1656
    GETTING ON AND OFF THE LOADER...1656
    GETTING READY FOR OPERATION...1656
    SAFETY SIGNS (DECALS)...1658
    DASH PANEL...1660
    LEARNING THE CONTROLS...1661
    THROTTLE CONTROL...1661
    CHOKE CONTROL...1661
    TO STOP THE ENGINE...1661
    PARKING BRAKE...1661
    STEERING LEVERS...1662
    HYDRAULIC CONTROLS...1663
      Foot Pedals...1663
      Lift Arm Operation...1663
      Tilt Operation (Bucket)...1663
      Auxiliary Lever Operation...1663
    BEFORE STARTING THE ENGINE...1664
    STARTING THE ENGINE...1665
      Normal Starting Condition...1666
      Cold Temperature Starting Condition...1667
    ATTACHMENTS & BUCKETS...1668
      Installation Of Attachments...1669
      Installation Of Bucket...1669
      Removal Of Bucket...1670
    OPERATING PROCEDURE...1670
      Filling The Bucket...1671
      Emptying The Bucket...1671
      Digging Into The Ground...1672
      Backfilling...1672
    PARKING THE BOBCAT LOADER...1673
    TRANSPORTING THE BOBCAT LOADER...1673
    BUCKET OF FORK INSTALLATION...1674
    BUCKET OF FORK REMOVAL...1675
  PREVENTIVE MAINTENANCE...1676
    MAINTENANCE SAFETY...1677
    SERVICE SCHEDULE...1678
    LIFT ARM STOP...1679
    OPERATOR CAB...1680
      Raising The Operator Cab...1680
      Lowering The Operator Cab...1681
    SEAT BAR SYSTEM...1682
      Seat Bar Inspection...1682
      Seat Bar Maintenance...1682
    REAR DOOR...1683
      Adjusting The Rear Door Latch...1683
    AIR CLEANER SERVICE...1683
    FUEL SYSTEM...1685
      Fuel System Service...1685
      Fuel Filter...1685
    ENGINE LUBRICATION SYSTEM...1686
    REPLACEMENT OF ENGINE OIL AND FILTER...1687
    COOLANT LEVEL...1688
    REMOVING COOLANT FROM THE COOLING SYSTEM...1688
    BELT ADJUSTMENT...1689
    GOVENOR...1690
      Govenor Adjustment...1690
      Govenor Oil Level...1690
    ELECTRICAL SYSTEM...1691
      Servicing The Electrical System...1693
      Using An Extra Battery (Jump Starting)...1693
      Installing A New Battery...1695
      Replacing The Battery...1695
    SPARK ARRESTOR MUFFLER...1696
    HYDRAULIC/HYDROSTATIC SYSTEM...1697
      Hydraulic/Hydrostatic Fluid Reservoir...1698
      changing And Adding Fluid...1698
      Replacment Of The Hydraulic Filter Element...1698
      Removing The Hydraulic Fluid...1699
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1700
    TIRE MAINTENANCE...1700
      Tire Rotation...1700
      Tire Installation On A Rim...1701
      Tire Pressure...1701
      Wheel Nuts...1701
    LUBRICATION OF THE BOBCAT LOADER...1701
    BOB-TACH FRAME...1702
    PIVOT PINS...1702
    BRAKE PEDAL ADJUSTMENT...1703
    AUXILIARY LOCKBOLT...1703
  TROUBLESHOOTING...1704
    TROUBLESHOOTING THE ENGINE...1706
    TROUBLESHOOTING THE DRIVE SYSTEM...1707
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...1708
  SAFETY SIGNS...1710
    WARNING - 6565980...1712
    SERVICE SCHEDULE - 6567875...1713
    WARNING - 6575855...1715
    WARNING - 6575854...1716
    IMPORTANT - 6560573...1717
    DANGER - 6575694...1717
  SPECIFICATIONS...1718
    SPECIFICATIONS...1720
    ENGINE...1720
    LOADER HYDRAULICS...1721
    ELECTRICAL...1721
    DRIVE SYSTEM...1721
    CAPACITIES...1721
    TIRES...1721
  WARRANTY...1722
6570275 (4-86) - 642B Service Manual...1724
  MAINTENANCE SAFETY...1726
  CONTENTS...1728
    FOREWORD...1730
    SAFETY INSTRUCTIONS...1732
    SERIAL NUMBER LOCATIONS...1733
    LOADER SERIAL NUMBER...1733
    ENGINE SERIAL NUMBER...1733
    DELIVERY REPORT...1733
    BOBCAT LOADER IDENTIFICATION...1734
  PREVENTIVE MAINTENANCE...1736
    SERVICE SCHEDULE...1738
    LIFTING AND BLOCKING THE BOBCAT LOADER...1739
      Procedure...1739
    TRANSPORTING THE BOBCAT LOADER...1740
      Procedure...1740
    LIFT ARM STOP...1741
      Procedure...1741
    OPERATORS CAB...1742
      Raising the Operator Cab...1742
      Lowering the Operator Cab...1743
    SEAT BAR SYSTEM...1744
    USING EXTRA BATTERY (JUMP START)...1745
      Procedure...1745
      Seat Bar Description...1744
      Seat Bar Inspection...1744
      Seat Bar Maintenance...1744
    REMOTE START SWITCH...1746
      Procedure...1746
  HYDRAULIC SYSTEM...1748
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1750
    TROUBLESHOOTING...1764
    HYDRAULIC SYSTEM INFORMATION...1765
      Flare Connections...1765
      Straight Thread O–ring Fitting...1765
      Tubelines and Hoses...1765
    LIFT CYLINDER...1766
      Checking the Lift Cylinder(s)...1766
      Removal and Installation...1766
    TILT CYLINDER...1768
      Checking the Tilt Cylinder...1768
      Removal and Installation...1768
      Rod End Seal...1769
    HYDRAULIC CONTROL VALVE...1770
      Checking the Main Relief Valve with Auxiliary Couplers (Opt.)...1770
      Checking The Main Relief Valve W/O Auxiliaries...1771
      Main Relief Valve Removal And Installation...1772
      Adjusting The Main Relief Valve...1772
      Removal And Installation...1773
    HYDRAULIC PUMP...1775
      Checking The Output Of The Hydraulic Pump...1775
      Removal And Installation...1776
    PORT BLOCK...1778
      Removal And Installation...1778
      Cold Weather By–Pass Valve...1779
      Case Drain Relief Valve...1780
    HYDRAULIC FLUID FILTER HOUSING...1781
      Removal and Installation...1781
      Sender Switch...1782
    HYDRAULIC FLUID RESERVOIR...1783
      Removal And Installation...1783
    HYDRAULIC CONTROL PEDALS...1784
      Removal And Installation...1784
      Adjustment...1784
    PEDAL LOCK LINKAGE...1785
      Adjustment...1785
  HYDROSTATIC SYSTEM...1786
    TROUBLESHOOTING...1788
      Chart...1788
    HYDROSTATIC SYSTEM INFORMATION...1789
      High Pressure Relief/Replenishing Valve Function...1789
    FRONT PANEL...1790
      Removal And Installation...1790
    STEERING LEVERS...1792
      Removal And Installation...1792
      Repairing The Steering Levers...1793
    STEERING LINKAGE...1794
      Steering Linkage Adjustment...1794
      Removal And Installation ...1795
      Repairing The Pintle Lever...1796
    HYDROSTATIC MOTOR...1797
      Removal And Installation...1797
    HYDROSTATIC PUMP...1799
      Checking Charge Pressure...1799
      Charge Pressure Relief Valve...1799
      Checking High Pressure Relief Valves...1800
      Removal And Installation...1801
      High Pressure Hose Routing...1803
      Tow Valves...1803
  DRIVE SYSTEM...1804
    PARKING BRAKE...1806
      Adjustment...1806
      Removal and Installation...1806
      Block and Pucks...1807
    AXLES, SEALS AND BEARINGS...1809
      Removal...1809
      Installation...1810
    FINAL DRIVE CHAIN...1813
      Removal...1813
      Installation...1813
    CHAINCASE FLUID...1814
      Replacing the Chaincase Fluid...1814
  MAIN FRAME...1816
    OPERATOR CAB...1818
      Removal And Installation...1818
    OPERATOR CAB GAS CYLINDER...1821
      Removal And Installation...1821
    REAR DOOR...1822
      Door Latch Adjustment...1822
      Removal And Installation...1823
    LIFT ARMS...1824
      Removal And Installation...1824
    BOB–TACH FRAME (40 Series)...1826
      Removal and Installation...1826
      Tilt Cylinder Rod End Seal...1827
      Disassembly and Assembly...1828
    BOB–TACH (50 Series)...1830
      Removal And Installation...1830
      Bob–Tach Lever And Wedge...1833
    FUEL TANK...1835
      Removal And Installation...1835
  ELECTRICAL SYSTEM...1836
    ELECTRICAL SCHEMATICS...1839
    ELECTRICAL SYSTEM...1848
      Description...1848
    TROUBLESHOOTING...1848
      Chart...1848
    BATTERY...1849
      Checking The Battery...1849
      Removal And Installation...1849
    ALTERNATOR...1850
      Checking The Alternator Output...1850
      Checking the Alternator Regulator...1850
      Removal and Installation...1851
      Disassembly And Assembly...1852
    STARTER...1855
      Checking The Starter...1855
      Removal And Installation...1855
      Disassembly And Assembly...1856
      Cleaning and Inspection...1857
      Replacing the Brushes...1857
  ENGINE SERVICE...1858
    TROUBLESHOOTING...1860
      Chart...1860
    VALVE CLEARANCE...1861
      Adjustment...1861
    ENGINE COMPRESSION...1862
      Checking...1862
    IGNITION TIMING...1863
      Procedure...1863
    DISTRIBUTOR...1864
      Removal And Installation...1864
      Point Gap Adjustment...1864
      Disassembly And Assembly...1865
      Checking Centrifugal Advance...1865
      Checking Vacuum Advance...1865
    CARBURETOR...1866
      Description...1866
      Removal And Installation...1869
      Disassembly And Assembly...1870
      Inspection...1870
      Adjustment...1870
      Governor Adjustment...1871
      Governor Oil Level...1871
    FUEL PUMP...1872
      Removal And Installation...1872
      Inspection...1872
      Check The Fuel Pump...1872
      Fuel Filter...1872
    ENGINE BELT SHIELD...1873
      Removal And Installation...1873
    REAR GRILL...1874
      Removal and Installation...1874
    ENGINE...1875
      Removal And Installation...1875
    OIL COOLER AND BLOWER HOUSING...1879
      Removal And Installation...1879
    RADIATOR...1882
      Removal And Installation...1882
    ENGINE MUFFLER...1883
      Removal And Installation...1883
    ENGINE FLYWHEEL AND U–JOINT...1884
      Removal And Installation...1884
      Flywheel Ring Gear...1884
    ROCKER ARMS...1885
      Removal...1885
      Inspection...1886
      Installation...1886
    CAMSHAFT...1889
      Removal And Installation...1889
      Inspection...1889
    CYLINDER HEAD...1890
      Removal And Installation...1890
      Inspection...1891
    VALVES...1892
      Removal...1892
      Installation...1892
      Reconditioning The Valve And Valve Seat...1893
      Valve Seat Inserts...1893
      Valve Guide...1894
      Valve Spring...1894
    PISTON AND CONNECTING ROD...1896
      Removal...1896
      Disassembly...1896
      Inspection...1897
      Assembly...1897
      Installation...1898
    PISTON PIN...1900
      Assembly Of The Tool...1900
      Removal Of The Piston Pin...1900
      Installation Of The Piston Pin...1901
    CYLINDER LINERS...1902
      Checking...1902
    CRANKSHAFT AND MAIN BEARINGS...1903
      Description...1903
      Removal...1903
      Checking...1903
      Checking Oil Clearance (Plastic Gauge)...1904
      Installation...1904
      Crankshaft End Play...1905
      Rear Oil Seal...1905
    TIMING BELT...1906
      Adjustment...1906
      Removal...1907
      Inspection...1908
      Assembly...1909
    FRONT CASE AND OIL PAN...1911
      Removal And Installation...1911
    OIL PUMP...1912
      Removal...1912
      Inspection...1912
      Installation...1912
      Relief Valve...1913
    FRONT CASE SEAL...1914
      Removal And Installation...1914
    WATER PUMP...1915
      Removal And Installation...1915
      Inspection...1915
    THERMOSTAT...1916
      Removal And Installation...1916
      Inspection...1916
    ANTI–DIESEL SYSTEM...1917
      Function...1917
      Removal and Installation...1917
  SPECIFICATIONS...1918
    LOADER SPECIFICATIONS...1920
      OPERATIONS & PERFORMANCE...1920
      ENGINE...1920
      HYDRAULIC SYSTEM...1921
      ELECTRICAL...1921
      DRIVE SYSTEM...1921
      CAPACITIES...1921
      TIRES...1921
    ENGINE SPECIFICATIONS...1922
      General...1922
      Cylinder Head...1922
      Cylinder Block...1922
      Piston...1922
      Piston Pin ...1922
      Connecting Rod...1923
      Crankshaft...1923
      Flywheel...1923
      Camshaft...1923
      Valve Train...1923
      Valve Guide...1924
      Valve Spring...1924
      Rocker Arm and Shaft...1925
      Oil Pump...1925
      Fuel Pump...1925
      Carburetor...1925
      Water Pump...1925
      Thermostat...1925
      Starter...1926
      Alternator...1926
      Distributor...1926
      Spark Plug...1926
      Engine Torque...1926
    TORQUE FOR GENERAL METRIC BOLTS...1927
    TORQUE SPECIFICATIONS FOR LOADER...1928
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...1929
      Specifications...1929
    DECIMAL AND MILLIMETER EQUIVALENTS...1930
    U.S. TO METRIC CONVERSION...1930
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...1931
  SERVICE MANUAL REVISIONS...1932
    642B-1...1932
    642B-2...1934
    642B-3...1936
    642B-4...1938
    642B-5...1940
    642B-6...1942
    642B-7...1944
    642B-8...1946
    642B-9...1948
    642B-10...1950
6570275 (6-12) - 642B Service Manual...1952
  MAINTENANCE SAFETY...1954
  CONTENTS...1956
    FOREWORD...1958
    SAFETY INSTRUCTIONS...1960
    SERIAL NUMBER LOCATIONS...1961
    LOADER SERIAL NUMBER...1961
    ENGINE SERIAL NUMBER...1961
    DELIVERY REPORT...1961
    BOBCAT LOADER IDENTIFICATION...1962
  PREVENTIVE MAINTENANCE...1964
    SERVICE SCHEDULE...1966
    LIFTING AND BLOCKING THE BOBCAT LOADER...1967
      Procedure...1967
    TRANSPORTING THE BOBCAT LOADER...1968
      Procedure...1968
    LIFT ARM STOP...1969
      Procedure...1969
    OPERATORS CAB...1970
      Raising the Operator Cab...1970
      Lowering the Operator Cab...1971
    SEAT BAR SYSTEM...1972
    USING EXTRA BATTERY (JUMP START)...1973
      Procedure...1973
      Seat Bar Description...1972
      Seat Bar Inspection...1972
      Seat Bar Maintenance...1972
    REMOTE START SWITCH...1974
      Procedure...1974
  HYDRAULIC SYSTEM...1976
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1978
    TROUBLESHOOTING...1992
    HYDRAULIC SYSTEM INFORMATION...1993
      Flare Connections...1993
      Straight Thread O–ring Fitting...1993
      Tubelines and Hoses...1993
    LIFT CYLINDER...1994
      Checking the Lift Cylinder(s)...1994
      Removal and Installation...1994
    TILT CYLINDER...1996
      Checking the Tilt Cylinder...1996
      Removal and Installation...1996
      Rod End Seal...1997
    HYDRAULIC CONTROL VALVE...1998
      Checking the Main Relief Valve with Auxiliary Couplers (Opt.)...1998
      Checking The Main Relief Valve W/O Auxiliaries...1999
      Main Relief Valve Removal And Installation...2000
      Adjusting The Main Relief Valve...2000
      Removal And Installation...2001
    HYDRAULIC PUMP...2003
      Checking The Output Of The Hydraulic Pump...2003
      Removal And Installation...2004
    PORT BLOCK...2006
      Removal And Installation...2006
      Cold Weather By–Pass Valve...2007
      Case Drain Relief Valve...2008
    HYDRAULIC FLUID FILTER HOUSING...2009
      Removal and Installation...2009
      Sender Switch...2010
    HYDRAULIC FLUID RESERVOIR...2011
      Removal And Installation...2011
    HYDRAULIC CONTROL PEDALS...2012
      Removal And Installation...2012
      Adjustment...2012
    PEDAL LOCK LINKAGE...2013
      Adjustment...2013
  HYDROSTATIC SYSTEM...2014
    TROUBLESHOOTING...2016
      Chart...2016
    HYDROSTATIC SYSTEM INFORMATION...2017
      High Pressure Relief/Replenishing Valve Function...2017
    FRONT PANEL...2018
      Removal And Installation...2018
    STEERING LEVERS...2020
      Removal And Installation...2020
      Repairing The Steering Levers...2021
    STEERING LINKAGE...2022
      Steering Linkage Adjustment...2022
      Removal And Installation ...2023
      Repairing The Pintle Lever...2024
    HYDROSTATIC MOTOR...2025
      Removal And Installation...2025
    HYDROSTATIC PUMP...2027
      Checking Charge Pressure...2027
      Charge Pressure Relief Valve...2027
      Checking High Pressure Relief Valves...2028
      Removal And Installation...2029
      High Pressure Hose Routing...2031
      Tow Valves...2031
  DRIVE SYSTEM...2032
    PARKING BRAKE...2034
      Adjustment...2034
      Removal and Installation...2034
      Block and Pucks...2035
    AXLES, SEALS AND BEARINGS...2037
      Removal...2037
      Installation...2038
    FINAL DRIVE CHAIN...2041
      Removal...2041
      Installation...2041
    CHAINCASE FLUID...2042
      Replacing the Chaincase Fluid...2042
  MAIN FRAME...2044
    OPERATOR CAB...2046
      Removal And Installation...2046
    OPERATOR CAB GAS CYLINDER...2049
      Removal And Installation...2049
    REAR DOOR...2050
      Door Latch Adjustment...2050
      Removal And Installation...2051
    LIFT ARMS...2052
      Removal And Installation...2052
    BOB–TACH FRAME (40 Series)...2054
      Removal and Installation...2054
      Tilt Cylinder Rod End Seal...2055
      Disassembly and Assembly...2056
    BOB–TACH (50 Series)...2058
      Removal And Installation...2058
      Bob–Tach Lever And Wedge...2061
    FUEL TANK...2063
      Removal And Installation...2063
  ELECTRICAL SYSTEM...2064
    ELECTRICAL SCHEMATICS...2067
    ELECTRICAL SYSTEM...2076
      Description...2076
    TROUBLESHOOTING...2076
      Chart...2076
    BATTERY...2077
      Checking The Battery...2077
      Removal And Installation...2077
    ALTERNATOR...2078
      Checking The Alternator Output...2078
      Checking the Alternator Regulator...2078
      Removal and Installation...2079
      Disassembly And Assembly...2080
    STARTER...2083
      Checking The Starter...2083
      Removal And Installation...2083
      Disassembly And Assembly...2084
      Cleaning and Inspection...2085
      Replacing the Brushes...2085
  ENGINE SERVICE...2086
    TROUBLESHOOTING...2088
      Chart...2088
    VALVE CLEARANCE...2089
      Adjustment...2089
    ENGINE COMPRESSION...2090
      Checking...2090
    IGNITION TIMING...2091
      Procedure...2091
    DISTRIBUTOR...2092
      Removal And Installation...2092
      Point Gap Adjustment...2092
      Disassembly And Assembly...2093
      Checking Centrifugal Advance...2093
      Checking Vacuum Advance...2093
    CARBURETOR...2094
      Description...2094
      Removal And Installation...2097
      Disassembly And Assembly...2098
      Inspection...2098
      Adjustment...2098
      Governor Adjustment...2099
      Governor Oil Level...2099
    FUEL PUMP...2100
      Removal And Installation...2100
      Inspection...2100
      Check The Fuel Pump...2100
      Fuel Filter...2100
    ENGINE BELT SHIELD...2101
      Removal And Installation...2101
    REAR GRILL...2102
      Removal and Installation...2102
    ENGINE...2103
      Removal And Installation...2103
    OIL COOLER AND BLOWER HOUSING...2107
      Removal And Installation...2107
    RADIATOR...2110
      Removal And Installation...2110
    ENGINE MUFFLER...2111
      Removal And Installation...2111
    ENGINE FLYWHEEL AND U–JOINT...2112
      Removal And Installation...2112
      Flywheel Ring Gear...2112
    ROCKER ARMS...2113
      Removal...2113
      Inspection...2114
      Installation...2114
    CAMSHAFT...2117
      Removal And Installation...2117
      Inspection...2117
    CYLINDER HEAD...2118
      Removal And Installation...2118
      Inspection...2119
    VALVES...2120
      Removal...2120
      Installation...2120
      Reconditioning The Valve And Valve Seat...2121
      Valve Seat Inserts...2121
      Valve Guide...2122
      Valve Spring...2122
    PISTON AND CONNECTING ROD...2124
      Removal...2124
      Disassembly...2124
      Inspection...2125
      Assembly...2125
      Installation...2126
    PISTON PIN...2128
      Assembly Of The Tool...2128
      Removal Of The Piston Pin...2128
      Installation Of The Piston Pin...2129
    CYLINDER LINERS...2130
      Checking...2130
    CRANKSHAFT AND MAIN BEARINGS...2131
      Description...2131
      Removal...2131
      Checking...2131
      Checking Oil Clearance (Plastic Gauge)...2132
      Installation...2132
      Crankshaft End Play...2133
      Rear Oil Seal...2133
    TIMING BELT...2134
      Adjustment...2134
      Removal...2135
      Inspection...2136
      Assembly...2137
    FRONT CASE AND OIL PAN...2139
      Removal And Installation...2139
    OIL PUMP...2140
      Removal...2140
      Inspection...2140
      Installation...2140
      Relief Valve...2141
    FRONT CASE SEAL...2142
      Removal And Installation...2142
    WATER PUMP...2143
      Removal And Installation...2143
      Inspection...2143
    THERMOSTAT...2144
      Removal And Installation...2144
      Inspection...2144
    ANTI–DIESEL SYSTEM...2145
      Function...2145
      Removal and Installation...2145
  SPECIFICATIONS...2146
    LOADER SPECIFICATIONS...2148
      OPERATIONS & PERFORMANCE...2148
      ENGINE...2148
      HYDRAULIC SYSTEM...2149
      ELECTRICAL...2149
      DRIVE SYSTEM...2149
      CAPACITIES...2149
      TIRES...2149
    ENGINE SPECIFICATIONS...2150
      General...2150
      Cylinder Head...2150
      Cylinder Block...2150
      Piston...2150
      Piston Pin ...2150
      Connecting Rod...2151
      Crankshaft...2151
      Flywheel...2151
      Camshaft...2151
      Valve Train...2151
      Valve Guide...2152
      Valve Spring...2152
      Rocker Arm and Shaft...2153
      Oil Pump...2153
      Fuel Pump...2153
      Carburetor...2153
      Water Pump...2153
      Thermostat...2153
      Starter...2154
      Alternator...2154
      Distributor...2154
      Spark Plug...2154
      Engine Torque...2154
    TORQUE FOR GENERAL METRIC BOLTS...2155
    TORQUE SPECIFICATIONS FOR LOADER...2156
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...2157
      Specifications...2157
    DECIMAL AND MILLIMETER EQUIVALENTS...2158
    U.S. TO METRIC CONVERSION...2158
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...2159
  SERVICE MANUAL REVISIONS...2160
    642B-1...2160
    642B-2...2162
    642B-3...2164
    642B-4...2166
    642B-5...2168
    642B-6...2170
    642B-7...2172
    642B-8...2174
    642B-9...2176
    642B-10...2178
    642B-11...2180
6720910 (10-91) - 642B, 742B, 743B Hand Controls Operation & Maintenance Manual...2182
  OPERATOR SAFETY WARNINGS...2184
  FOREWORD...2186
    CONTENTS...2186
    REFERENCE INFORMATION...2186
    SAFETY INSTRUCTIONS...2188
    FIRE PREVENTION...2189
    SERIAL NUMBER LOACATIONS...2190
    DELIVERY REPORT...2190
    BOBCAT SKID STEER LOADER IDENTIFICATION...2191
    SAFETY SIGNS (DECALS)...2192
  OPERATING INSTRUCTIONS...2194
    INSTRUMENT PANEL...2196
    THROTTLE CONTROL...2196
    PARKING BRAKE...2197
    STEERING LEVERS...2198
    HYDRAULIC CONTROLS...2199
      Hand Controls...2199
      Lift Arm Operation...2199
      Tilt Operation (Bucket)...2199
      Auxiliary Pedal Operation...2199
    DAILY INSPECTION...2200
    GETTING READY FOR OPERATION...2201
    STARTING THE ENGINE...2203
      Normal Starting Condition...2203
      Cold Temperature Starting Condition...2204
      Warming The Hydraulic/Hydrostatic System...2205
    STOPPING THE ENGINE...2205
    ATTACHMENTS & BUCKETS...2206
      Installation & Removal...2207
    OPERATING PROCEDURE...2208
      Filling The Bucket...2209
      Emptying The Bucket...2209
      Digging Into The Ground...2210
      Leveling The Ground (Using Lift Arms In Float Position)...2211
      Backfilling...2211
    PARKING THE BOBCAT LOADER...2212
    TRANSPORTING THE BOBCAT LOADER...2212
    LIFTING THE BOBCAT LOADER...2213
    TOWING THE BOBCAT LOADER...2213
  PREVENTIVE MAINTENANCE...2214
    MAINTENANCE SAFETY...2216
    SERVICE SCHEDULE...2218
    LIFT ARM SUPPORT DEVICE...2219
    OPERATOR CAB...2219
      Raising The Operator Cab...2220
      Lowering The Operator Cab...2221
    SEAT BAR SYSTEM...2222
      Seat Bar Inspection...2222
      Seat Bar Maintenance...2222
    REAR DOOR...2223
      Adjustment...2223
    AIR CLEANER SERVICE (642B, 742B)...2224
    AIR CLEANER SERVICE (743B)...2225
    FUEL SYSTEM (642B, 742B)...2226
      Fuel Specifications...2226
      Filling The Fuel Tank...2226
      Fuel Filter...2226
    FUEL SYSTEM (743B)...2227
      Fuel Specifications...2227
      Filling The Fuel Tank...2227
      Fuel Filter...2227
      Removing Air From The Fuel System...2228
    ENGINE LUBRICATION SYSTEM (642B, 742B)...2229
      Checking Engine Oil...2229
      Engine Oil And Filter Replacement...2229
    ENGINE LUBRICATION SYSTEM (743B)...2230
      Checking Engine OIl...2230
      Replacing Oil And Filter...2230
    COOLING SYSTEM...2231
      Checking The Coolant Level...2231
      Cleaning The Cooling System...2231
      Removing Coolant From The Cooling System...2232
    ALTERNATOR BELT ADJUSTMENT...2233
    GOVENOR (642B, 742B)...2234
      GovenorBelt Adjustment...2234
      Govenor Adjustment...2234
      Govenor Oil Level...2234
    ELECTRICAL SYSTEM...2235
      Description...2235
      Electrical System Service...2235
      Using A Booster Battery (Jump Starting)...2235
      Battery Removal And Installation...2236
    HYDRAULIC/HYDROSTATIC SYSTEM...2237
      Checking And Adding Fluid...2237
      Replacement Of The Hydraulic/Hydrostatic Filter Element...2237
      Removing The Hydraulic Fluid...2238
    SPARK ARRESTOR MUFFLER...2239
    TIRE MAINTENANCE...2240
      Wheel Nuts...2240
      Tire rotation...2240
      Tire Inflation...2240
    FINAL DRIVE TRANSMISSION (CHAINCASE)...2240
      Checking And Adding Oil...2240
    LUBRICATION OF THE BOBCAT LOADER...2241
    BOB-TACH...2242
    PIVOT PINS...2242
    PARKING BRAKE ADJUSTMENT...2242
  TROUBLESHOOTING...2244
    TROUBLESHOOTING THE ENGINE...2246
    TROUBLESHOOTING THE DRIVE SYSTEM...2247
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...2248
  SAFETY SIGNS...2250
    WARNING - 6579511...2252
    SERVICE SCHEDULE - 6567875...2253
    WARNING - 6702997...2255
    WARNING - 6579528...2256
    WARNING - 6577754...2256
    DANGER - 6702302...2256
    DANGER - 6702301...2256
    IMPORTANT - 6560573...2257
  SPECIFICATIONS...2258
    642B LOADER SPECIFICATIONS...2260
      LOADER DIMENSIONS...2260
      OPERATION & PERFORMANCE...2260
      ENGINE...2260
      HYDRAULIC SYSTEM...2261
      ELECTRICAL...2261
      DRIVE SYSTEM...2261
      CAOPACITIES...2261
      TIRES...2261
    742B LOADER SPECIFICATIONS...2262
      LOADER DIMENSIONS...2262
      OPERATIONS & PERFORMANCE...2262
      ENGINE...2262
      HYDRAULIC SYSTEM...2263
      ELECTRICAL...2263
      DRIVE SYSTEM...2263
      CAPACITIES...2263
      TIRES...2263
    743B LOADER SPECIFICATIONS...2264
      LOADER DIMENSIONS...2264
      OPERATIONS & PERFORMANCE...2264
      ENGINE...2264
      HYDRAULIC SYSTEM...2265
      ELECTRICAL...2265
      DRIVE SYSTEM...2265
      CAPACITIES...2265
      TIRES...2265
    ATTACHMENTS & ACCESSORIES...2266
    ADDITIONAL PUBLICATIONS...2269
  WARRANTY...2270
6722526 (03-93) - 645 Service Manual...2272
  MAINTENANCE SAFETY...2273
  FOREWORD...2276
  CONTENTS...2278
    SAFETY INSTRUCTIONS...2280
    SERIAL NUMBER LOCATIONS...2281
      LOADER SERIAL NUMBER...2281
      ENGINE SERIAL NUMBER...2281
    DELIVERY REPORT...2281
    BOBCAT SKID STEER LOADER IDENTIFICATION...2282
  PREVENTIVE MAINTENANCE...2284
    SERVICE SCHEDULE...2286
    PREVENTIVE MAINTENANCE...2287
    LIFTING AND BLOCKING THE BOBCAT LOADER...2287
      Procedure...2287
    PARKING THE BOBCAT LOADER...2288
      Procedure...2288
    TRANSPORTING THE BOBCAT LOADER...2288
    LIFT ARM SUPPORT DEVICE...2289
      To Engage Lift Arm Support Device...2289
      To Disengage Lift Arm Support Device...2289
    OPERATOR CAB...2290
      Description...2290
      Raising the Operator Cab...2290
      Lowering the Operator Cab...2290
    SEAT BAR RESTRAINT SYSTEM...2291
      Description...2291
      Seat Bar Inspection...2292
      Seat Bar Maintenance...2292
    AIR CLEANER SERVICE...2293
      Replacement of the Filter Element...2293
    FUEL SYSTEM...2295
      Fuel Specifications...2295
      Filling the Fuel Tank...2295
      Fuel Filter...2295
      Removing Air From the Fuel System...2296
    ENGINE LUBRICATION SYSTEM...2297
      Checking Engine Oil...2297
      Replacing Oil and Filter...2297
    ENGINE COOLING SYSTEM...2299
      Coolant Level...2299
      Cleaning the Cooling System...2299
      Removing Coolant from the Cooling System...2299
    ALTERNATOR BELT ADJUSTMENT...2301
      Adjusting the Alternator Belt...2301
    USING A BOOSTER BATTERY (JUMP STARTING)...2302
      Procedure...2302
    HYDRAULIC / HYDROSTATIC SYSTEM...2303
      Checking and Adding Fluid...2303
      Hydraulic / Hydrostatic Filter Replacement...2304
      Removing the Hydraulic Fluid...2304
    SPARK ARRESTOR MUFFLER...2305
      Cleaning Procedure...2305
    TIRE MAINTENANCE...2306
      Wheel Nuts...2306
      Tire Rotation...2306
      Tire Mounting...2306
    FINAL DRIVE TRANSMISSION (CHAINCASE) ...2307
      Checking and Adding Oil...2307
    LUBRICATION OF THE BOBCAT LOADER...2308
      Procedure...2308
    U-JOINTS LUBRICATION...2310
      Procedure...2310
    REMOTE START SWITCH...2310
      Procedure...2310
  HYDRAULIC SYSTEM...2312
    HYDRAULIC / HYDROSTATIC SCHEMATICS...2314
    HYDRAULIC SYSTEM...2318
      TROUBLESHOOTING...2318
    HYDRAULIC SYSTEM INFORMATION...2319
      Flare Connections...2319
      O-ring Face Seal Connections...2319
      Straight Thread O-ring Fitting...2319
      Tubelines and Hoses...2319
    LIFT CYLINDER...2320
      Checking the Lift Cylinder(s)...2320
      Removal and Installation...2320
    TILT CYLINDER...2322
      Checking the Tilt Cylinder...2322
      Removal and Installation...2322
    HYDRAULIC CONTROL VALVE...2324
      Checking the Main Relief Valve W/Auxiliary Couplers (Opt.)...2324
      Main Relief Valve Removal and Installation...2325
      Adjusting the Main Relief Valve...2325
      Removal and Installation...2326
    HYDRAULIC PUMP...2328
      Checking the Output of the Hydraulic Pump...2328
      Removal and Installatio...2329
    PORT BLOCK...2330
      Removal and Installation...2330
      Cold Weather By-Pass Valve...2331
      Case Drain Relief Valve...2332
    HYDRAULIC FLUID RESERVOIR...2333
      Removal and Installation...2333
    HYDRAULIC CONTROL PEDALS ...2334
      Removal and Installation...2334
      Adjustment...2334
    PEDAL INTERLOCK LINKAGE...2335
      Installation...2335
      Adjustment...2335
    HYDRAULIC FLUID FILTER HOUSING...2336
      By-Pass Removal and Installation...2336
  HYDROSTATIC SYSTEM...2338
    TROUBLESHOOTING...2340
    HYDROSTATIC SYSTEM INFORMATION...2341
      High Pressure Relief / Replenishing Valve Function...2341
    FRONT PANEL...2342
      Removal and Installation...2342
    STEERING LEVERS ...2344
      Removal and Installation...2344
      Repairing...2345
    STEERING LINKAGE...2346
      Steering Linkage Adjustment...2346
      Removal and Installation...2347
      Repairing the Pintle Lever...2348
    HYDROSTATIC MOTOR...2349
      Removal and Installation...2349
    HYDROSTATIC PUMP...2351
      Checking Charge Pressure...2351
      Charge Pressure Relief Valve...2351
      Checking High Pressure Relief Valves...2352
      Removal and Installation...2353
      Hydrostatic Pump Rear Mount...2356
      High Pressure Hose Routing...2356
      Tow Valves...2356
  DRIVE SYSTEM...2358
    PARKING BRAKE...2360
      Adjustment...2360
      Removal and Installation...2361
      Brake Block and Pads...2362
      Brake Discs Removal and Installation...2364
    MOTOR CARRIER...2365
      Shaft Seal Replacement...2365
      Removal and Installation...2367
      Disassembly and Assembly...2368
    AXLE SEAL...2369
      Removal and Installation...2369
    AXLE, SPROCKET AND BEARINGS...2372
      Removal and Installation...2372
    DRIVE CHAIN...2376
      Removal and Installation...2376
    CHAINCASE FLUID...2377
      Replacing the Chaincase Fluid...2377
  MAIN FRAME...2378
    OPERATOR CAB ...2380
      Removal and Installation...2380
    OPERATOR CAB GAS CYLINDER...2383
      Removal and Installation...2383
    REAR DOOR...2384
      Door Latch Adjustment...2384
      Removal and Installation...2385
    REAR GRILLE...2386
      Removal and Installation...2386
    BOB-TACH...2387
      Removal and Installation...2387
      Bob-Tach Lever and Wedge...2390
    LIFT ARMS...2392
      Removal and Installation...2392
    FUEL TANK...2394
      Removal and Installation...2394
      Fuel Tank Sender Switch...2395
  ELECTRICAL SYSTEM...2396
    ELECTRICAL SCHEMATICS...2398
    ELECTRICAL SYSTEM INFORMATION...2402
      Description...2402
    TROUBLESHOOTING...2402
    BATTERY...2403
      Checking the Battery...2403
      Removal and Installation...2403
    ALTERNATOR BELT SHIELD...2404
      Removal and Installation...2404
    ALTERNATOR...2405
      Alternator Output Test...2405
      Rectifier (Diode) Test...2405
      Alternator Regulator Test...2406
      Removal and Installation...2407
      Disassembly and Assembly...2408
      Stator Continuity Test...2408
      Stator Ground Test ...2408
      Rotor Continuity Test...2408
      Rotor Gound Test...2408
      Rectifier Continuity (Diode) Test...2409
      Parts Identification...2410
    STARTER...2411
      Checking the Starter...2411
      Removal and Installation...2411
      Disassembly and Assembly...2412
      Replacing the Brushes...2413
      Cleaning and Inspection...2414
      Parts Identification...2415
  ENGINE SERVICE...2416
    TROUBLESHOOTING...2418
    FUEL FILTER...2419
      Replacing the Fuel Filter...2419
      Removing Air From the Fuel System...2419
    GLOW PLUGS...2419
      Checking...2419
    FUEL INJECTION PUMP...2420
      Removal and Installation...2420
      Timing the Injection Pump...2421
      Checking the Injection Pump...2422
    FUEL INJECTOR NOZZLES...2423
      Removal and Installation...2423
      Checking the Nozzles...2424
    ENGINE...2425
      Removal and Installation...2425
    RADIATOR AND OIL COOLER...2427
      Removal and Installation...2427
    BLOWER HOUSING...2428
      Removal and Installation...2428
    ENGINE FLYWHEEL AND U-JOINT...2429
      Removal and Installation...2429
      Flywheel Ring Gear...2429
    MUFFLER...2430
      Removal and Installation...2430
    CYLINDER HEAD...2431
      Removal...2431
      Disassembly...2432
      Servicing...2432
      Valve Guide Installation...2434
      Assembly...2436
      Installation...2436
    ENGINE REPAIR...2437
      Gearcase Removal...2437
      Timing Gear, Camshaft and Oil Pump Removal...2439
      Pistons and Crankshaft Removal...2440
      Timing Gear and Camshaft Service...2442
      Servicing the Connecting Rods and Pistons...2443
      Crankshaft Service...2445
      Cylinder Liner Service...2446
      Lubrication System...2447
      Oil Pump Service...2448
      Water Pump Service...2448
    ENGINE ASSEMBLY...2450
      Crankshaft Installation...2450
      Installing the Pistons...2450
      Installing the Camshaft and Timing Gears...2450
      Gearcase Installation...2452
  SPECIFICATIONS...2454
    LOADER SPECIFICATIONS...2456
      LOADER DIMENSIONS...2456
      OPERATION & PERFORMANCE...2456
      ENGINE...2456
      HYDRAULICS SYSTEM...2457
      ELECTRICAL...2457
      DRIVE SYSTEM...2457
      CAPACITIES...2457
      TIRES...2457
    ENGINE SPECIFICATIONS...2458
      Fuel Injection Nozzles...2458
      Fuel Injection Pump...2458
      Cylinder Head...2458
      Valves...2458
      Valve Springs...2458
      Rocker Arms...2458
      Camshaft...2458
      Cylinders...2459
      Piston Rings...2459
      Pistons...2459
      Crankshaft...2459
      Oil Pump...2459
      Engine Oil...2459
    ENGINE BOLT TORQUES...2460
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...2462
      Specifications...2462
    DECIMAL AND MILLIMETER EQUIVALENTS...2463
    U.S. TO METRIC CONVERSION...2463
    TORQUE FOR GENERAL METRIC BOLTS...2464
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...2465
    
Bobcat Skid-Steer Loaders 641, 642, 642B, 643, 645 Repair Service Manuals