DOWNLOAD PDF Bobcat 641 642 642B 643 Operation & Maintenance Manual

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Operation & Maintenance Manual

6570241 (4–89) Revised (8–96)

Printed in U.S.A.

© Melroe Company 1996

OPERATOR SAFETY WARNINGS CORRECT Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W–2001–1285

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

B–10731

Never use the loader without instructions. See machine signs (decals), Operations & Maintenance

Manual and Handbook.

CORRECT

CORRECT

WRONG

B–7403

B–6582

B–13418

Always use the seat bar and fasten seat belt snugly.

Always keep feet on the pedals when operating loader.

Never use loader without operator cab with ROPS and FOPS approval.

Never use loader as man lift or elevating device for personnel.

WRONG

WRONG

WRONG

B–6578

B–6585

B–6595

Keep bystanders away from work area.

always carry bucket or attachments as low as possible.

Do not travel or turn with lift arms up.

Load, unload and turn on flat level ground.

WRONG

WRONG

WRONG

B–6587

B–6594

B–6591

Never exceed rated operating capacity.

Never leave loader with engine running or with lift arms up.

To park, engage parking brake and put attachment flat on the ground.

Do not use loader in atmosphere with explosive dust or gas or where exhaust can contact flammable material.

Never carry riders.

Never modify equipment.

Use only attachments approved

by Melroe Company for this model loader.

SAFETY EQUIPMENT The Bobcat loader must be equipped with safety items necessary for each job. Ask your dealer about attachments and accessories.

1. SEAT BELT: Check belt fasteners and check for damaged webbing or buckle.

2. SEAT BAR: When up, it must lock the pedals.

3. OPERATOR CAB (ROPS and FOPS): It must be on the loader with all fasteners tight.

4. HANDBOOK: Must be in the cab.

5. SAFETY SIGNS (DECALS): Replace if damaged.

6. SAFETY TREADS: Replace if damaged.

7. GRAB HANDLES: Replace if damaged.

8. LIFT ARM SUPPORT DEVICE OSW02–0498 9. PARKING BRAKE

641,642,642B,643Operation&MaintenanceManual#6570241–ContentsSection

CONTENTS FOREWORD FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 MACHINE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

SAFETY

OPERATING INSTRUCTIONS

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

PREVENTIVE MAINTENANCE

REFERENCE INFORMATION Write the correct information for YOUR Bobcat loader in the spaces below.

Always use these numbers when referring to your Bobcat loader.

Loader Serial Number . . . . . . . .

Engine Serial Number . . . . . . . .

TROUBLESHOOTING

MACHINE SIGN TRANSLATIONS

NOTES:

SPECIFICATIONS

YOUR LOADER DEALER: ADDRESS: PHONE: Melroe Company P.O. Box 128 Gwinner, ND 58040–0128 Melroe Europe J. Huysmanslaan 59 B–1651 LOT BELGIUM

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FOREWORD FOREWORD This Operation & Maintenance Manual was written to give the owner/operator instructions on the safe operation and maintenance of the Bobcat loader. READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR LOADER. If you have any questions, see your Bobcat loader dealer.

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi OPTIONS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

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SERIAL NUMBER LOCATIONS

A

Always use the serial number of the loader when requesting service information or when ordering parts.

Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

Loader Serial Number

LOADER SERIAL NUMBER The loader serial number plate is located on the inside of the left upright, above the grill [A].

Explanation of loader Serial Number: XXXX

B–12679

XXXXX Module 2. – Production Sequence (Series)

B

641

642

Module 1. – Model/Engine Combination Engine Serial Number

1. The four digit Model/Engine Combination Module number identifies the model number and engine combination.

Engine Serial Number

2. The five digit Production Sequence Number identifies the order which the loader is produced.

ENGINE SERIAL NUMBER B–2249

641 – The engine serial number is on the blower housing on the right side of the engine [B].

C

642 – The engine serial number is on top of the valve cover of the engine [B].

643

B–2796

642B

643 – The engine serial number is on the left side of the engine block, near the fuel injection pump [C].

Engine Serial Number

642B – The engine serial number is located on the top left surface of the block [C].

B–9644

Engine Serial Number

B–9644

D

DELIVERY REPORT The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [D].

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BOBCAT LOADER IDENTIFICATION

FRONT LIGHTS (OPTIONAL)

GRAB HANDLES OPERATOR SEAT STEERING LEVERS SEAT BELT TILT CYLINDER

FRONT AUXILIARY QUICK COUPLERS (OPTIONAL ON 642B) BUCKET

SAFETY TREAD

BUCKET STEPS

REAR LIGHT (Opt. on 642B)

OPERATOR CAB (ROPS & FOPS)

SEAT BAR UPRIGHT

LIFT ARM

REAR GRILL LIFT ARM SUPPORT DEVICE LIFT CYLINDER

REAR DOOR

TIRES*

B–7377 C–2878

* TIRES – Flotation tires (optional) are shown. The Bobcat loader is factory equipped with standard tires.

BUCKET – Several different buckets and other attachments are available for the Bobcat loader.

ROPS, FOPS – Roll Over Protective Structure, per SAE J1040, and Falling Object Protective Structure per SAE J1043.

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OPTIONS AND ACCESSORIES 641, 642, 642B & 643 Bobcat loaders are equipped with the following standard items: Bob–Tach Seat Belt Spark Arrestor Exhaust System Seat Bar Operator Cab (W/ROPS & FOPS Approval) Parking Brake Gauges/Warning Lights Below is a listing of the optional equipment which is available through your Bobcat loader dealer.

Tires 7.00–15, 6 PR . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.00–16.5, 6 PR Flotation . . . . . . . . . . . . . . . . .

10.00–16.5, 8 PR Heavy Duty Flotation . . . . . .

Std. Opt. & FA FA

Operator Cab Suspension Seat . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Lights (Front & Rear) . . . . . . . . . . . . .

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Back–Up Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heated Enclosed Cab . . . . . . . . . . . . . . . . . . . . . .

Top Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Enclosure Panels . . . . . . . . . . . . . . . . . . . . .

Vinyl Cab Enclosure . . . . . . . . . . . . . . . . . . . . . . .

Hand Control Conversion . . . . . . . . . . . . . . . . . . .

Cover Kit (Pedals Area) . . . . . . . . . . . . . . . . . . . .

Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . .

Flasher Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Strobe or Rotating Beacon Light . . . . . . . . . . . . .

3’’ Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FA (Std. in Europe) FA (Std. in Europe) FA (Std. in Europe) FA FA FA (Std. in Europe) FA (Std. in Europe) FA FA FA FA (Std. in Europe) FA FA FA FA

Hydraulics Front Auxiliary Hydraulics . . . . . . . . . . . . . . . . . .

Rear Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . .

Hydraulic Bucket Positioning . . . . . . . . . . . . . . . .

Opt. & FA (Std. in Europe) Opt. & FA Opt. & FA (Std. in Europe)

Other Catalytic Purifier . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . .

Single Point Lift . . . . . . . . . . . . . . . . . . . . . . . . . . .

Locking Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator Screen Kit . . . . . . . . . . . . . . . . . . . . . . . .

Tailgate Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FA FA FA FA FA FA (Std. in Europe)

Std. = Standard Equipment Opt. = Factory Installed Option FA = Field Installed Accessory

Specifications subject to change without notice

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SAFETY SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi, xii FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv, xv

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SAFETY

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BEFORE OPERATING THE BOBCAT LOADER Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see this symbol follow safety message to avoid personal injury or death.

Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W–2001–1285 B–10731

The Bobcat loader must be in good operating condition before use.

Check all of the items on the Service Schedule Decal or as shown in this Operation & Maintenance Manual under Daily Inspection.

Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

This notice identifies procedures which must be followed to avoid damage to the machine.

I–2019–0284

W–2044–1285

SAFE OPERATION NEEDS A QUALIFIED OPERATOR* A QUALIFIED OPERATOR MUST DO THE FOLLOWING:

• UNDERSTAND THE WRITTEN INSTRUCTIONS, RULES AND REGULATIONS • The written instructions from Melroe Company include the delivery report, Operation & Maintenance Manual and plastic handbook, EMI Safety Manual and machine signs (decals).

• Check the rules and regulations at your location. The rules may include an employer’s work safety requirements.

Regulations may apply to local driving requirements or use of Slow Moving Vehicle emblem. Regulations may identify a hazard such as a utility line.

• HAVE TRAINING WITH ACTUAL OPERATION • Operator training must consist of a demostration and verbal instruction. This training is given by your dealer before the loader is delivered.

• The new operator must start in an area without bystanders and use all the controls until he can operate the loader safely under all conditions of the work area. Always fasten seat belt and lower seat bar before operating.

• KNOW THE WORK CONDITIONS • For each material to be handled, the operator must know how to avoid exceeding the rated operating capacity of the loader. For example, in handling certain loose material with a given bucket, he must know whether he can safely take a full load, or only part of a bucket load.

• The operator must know any prohibited uses or work areas, for example, he needs to know about excessive slopes.

• Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hearing

protection or loader special applications kit are required for some work. See your dealer about Melroe Safety equipment.

* For an operator be qualified, he must not use drugs or alcoholic drinks which impair his alertness or coordination while working. An operator who is taking prescription drugs must get medical advice to determine if he can safely operate a machine.

SI02–0498

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SAFETY INSTRUCTIONS SAFETY IS THE OPERATOR’S RESPONSIBILITY The Skid Steer Loader is a highly maneuverable and compact machine. In operation, it is rugged and useful under a wide variety of conditions. This presents an operator with hazards associated with off highway, rough terrain applications. The loader has an internal combustion engine with resultant heat and exhaust. All exhaust gases can kill or cause illness so the loader must be used with adequate ventilation. The loader has a spark arrestor muffler which is required for operation in certain areas.

The dealer explains the capabilities and restrictions of the loader and attachments for each application. The dealer demonstrates the safe operation of the loader according to Melroe’s instructional materials; which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments. The attachments and buckets are designed for rated capacity and secure fastening to the loader. The user must check with the dealer, or Melroe Company literature, to determine safe loads of materials of specified densities for his loader–attachment combination.

The following publications provide information on the safe use and maintenance of the loader and attachments: • The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.

• The Operation and Maintenance Manual delivered with the loader gives operating information as well as routine maintenance and service procedures. It is a part of the loader and must stay in the machine. (A container is provided inside the cab.) Replacement Operation and Maintenance Manuals can be ordered from your Bobcat loader dealer.

• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are shown in the Operation and Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.

• The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.

• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.

• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and repair work.

• The Skid–Steer Loader Operator Training Course is available through your local Bobcat dealer. This course provides information for safe and efficient operation of the Bobcat loader. The course is available in English and Spanish versions.

• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

The dealer and owner/operator review the recommended uses of the loader and attachments when the loader is delivered.

If the owner/operator will be using the loader for a different application(s) he must ask the dealer for recommendations on the new use.

Call Before You Dig 1–888–258–0808 When you call, you will be directed to a location in your state/city for information about burried lines (telephone, cable TV, water, sewer, gas,etc.).

SI01–0398

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FIRE PREVENTION The loader has several components that are at high temperature under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will increase the fire hazard. The loader must be cleaned as often as necessary to avoid this accumulation. Flammable debris in the engine compartment is a fire hazard when the loader is parked with a hot engine.

The spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot.

• Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazard and overheating.

• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

• Do not use ether or starting fluids on this engine. It has glow plugs. These starting aids can cause explosion and injure you or bystanders.

• Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.

• Stop the engine and let it cool before adding fuel. No smoking!

• Use the procedure in the Operation & Maintenance Manual for connecting the battery.

• Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler.

• Know where fire extinguishers and first aid kits are located and how to use them.

A fire extinguisher is available from your Bobcat dealer. The fire extinguisher can be installed in the location shown [A].

A

P–10650

SI03–0398

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MACHINE SIGNS (DECALS) Follow the instructions on all the Machine Signs (Decals) that are on the loader. Replace any damaged machine signs (decals) and be sure they are in the correct locations. Machine signs (decals) are available from your Bobcat loader dealer.

6561385 (642 Only)

6569021

6565927 (641 & 643 Only)

6565990

6569119

6557565

6577754 (2) 6561377

6577826 6710358

6579509

6579528 6579510

6561383 (641, 642 & 643 Only) (642B Optional) 6579639

B–7377

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MACHINE SIGNS (DECALS) (Cont’d)

6561384 (642 & 642B Only) 6560573

6561379 (641 & 643 Only)

*6567694

6559569 (641 & 643 Only)

*6579511

*6567875

* Located inside the engine compartment.

C–2878

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641,642,642B,643Operation&MaintenanceManual#6570241–ContentsSection

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OPERATING INSTRUCTIONS ATTACHMENTS & BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation and Removal (641, 642, 643) (Optional on 642B) . . . . . . . . . . 15 Installation of Attachment (642B Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installation of Bucket (642B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Removal of Bucket (642B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 CHOKE CONTROL (642 & 642B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

OPERATING INSTRUCTIONS

ENGINE STOP CONTROL (643) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 GETTING READY FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Getting On and Off the Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Machine Signs (Decals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Auxiliary Lever Operation (Optional on 642B) . . . . . . . . . . . . . . . . . . . . . . . . . 7 Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Lift Arm Float Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Tilt Operation (Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 One Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Three Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 LEARNING THE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 LIFTING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Digging Into the Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Emptying the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Filling the Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Leveling the Ground (Using Lift Arms in Float Position) . . . . . . . . . . . . . . . . 21 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PARKING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Normal Starting Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cold Temperature Starting Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 STOPPING THE ENGINE (641, 642 & 642B) . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TOWING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 –1–

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INSTRUMENT PANEL

A

One Piece The following items are located on the one piece instrument panel [A]:

641, 642, 642B, 643 1

6

4

10

8

1. HOURMETER – Records the total operating hours of the loader.

2. KEY SWITCH (641 & 643 Only) – Controls preheat operation and starting the engine.

642B Only – Controls starting and stopping the engine.

5

3. VOLTMETER – Shows the condition of the battery and the rate of charge.

2

3

7

9

4. FUSE (ACCESSORIES) – To protect the electrical system from overload.

5. FUSE (IGNITION) – To protect the electrical system from overload.

B–7524

6. ENGINE WARNING LIGHT – Engine oil pressure is low. Stop the engine if this light comes ON. 7. TRANSMISSION WARNING LIGHT – Low transmission charge pressure, hydraulic filter needs replacement or high fluid temperature. Stop the engine if this light comes ON. 8. LIGHT SWITCH – Controls the work and travel lights.

9. FUEL GAUGE – Shows the amount of fuel in the fuel tank.

10. ENGINE TEMPERATURE GAUGE – Shows the engine coolant temperature.

–3–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

INSTRUMENT PANEL (Cont’d)

A

Three Piece

641, 642B DELUXE CAB, 643 6

The following items are located on the three piece instrument panel [A] & [B]:

3

13

1

1. LIGHT SWITCH – Controls the work and travel lights.

2. KEY SWITCH (641 & 643 Only) – For starting, stopping and preheating the engine.

7 8

4

3. FUSE (ACCESSORIES) – To protect the electrical system from overload.

2 10 12

4. FUSE (IGNITION) – To protect the electrical system from overload.

5. HOURMETER – Records the total operating hours of the loader (642B standard cab only).

B–12526

6. HOURMETER – Records the total operating hours of the loader (642B deluxe cab, standard on 641 & 643).

B

642B STANDARD CAB

7. FUEL GAUGE – Shows the amount of fuel in the fuel tank (642B deluxe cab, standard on 641 & 643).

3

1

8. ENGINE TEMPERATURE GAUGE – Shows the engine coolant temperature (642B deluxe cab, standard on 641 & 643).

9. ENGINE WARNING LIGHT – Engine oil pressure is low. Stop the engine if the light comes ON (642B standard cab only).

4

10. ENGINE WARNING LIGHT – Engine oil pressure is low. Stop the engine if the light comes ON (642B deluxe cab, 641 & 643).

5 2

11. TRANSMISSION WARNING LIGHT – Low transmission charge pressure, hydraulic filter needs replacement or high fluid temperature. Stop the engine if the light comes ON (642B standard cab only).

9

11 B–12625

12. TRANSMISSION WARNING LIGHT – Low transmission charge pressure, hydraulic filter needs replacement or high fluid temperature. Stop the engine if the light comes ON (642B deluxe cab, 641 & 643).

13. VOLTMETER – Shows the condition of the battery and the rate of charge (642B deluxe cab, 641 & 643).

–4–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

LEARNING THE CONTROLS

A

All the controls are within easy reach of the operator.

Learn the action of the steering and hydraulic controls.

The loader has a seat belt and seat bar. When the seat bar is raised the foot pedals are locked and the lift and tilt pedals cannot be operated.

1 2

ENGINE SPEED CONTROL The engine speed control (Item 1) [A] is at the right side of the operator’s seat. Engine RPM is controlled by moving the engine speed control forward to increase the engine RPM and backward to decrease the engine RPM. CHOKE CONTROL (642 & 642B) The choke control (Item 2) [A] is at the right side of the seat by the engine speed control lever. Pull the knob up to engage the choke and push down to release the choke.

B–9409

STOPPING THE ENGINE (641, 642 & 642B)

B

Pull the engine speed control (Item 1) [A] fully backward to decrease the engine RPM. Turn the key switch to the OFF position.

ENGINE STOP CONTROL (643) The engine stop control (Item 2) [A] is at the right side of the seat by the engine speed control lever. Pull up on the engine stop control to stop the engine. Push the control down after the engine has stopped. Turn the key switch to the OFF position.

NOTE: The engine stop control (643) and the choke control (642 & 642B), do not exist on the 641.

PARKING BRAKE Lock the brake by pushing down on the top (toe) of the pedal [B].

B–3745 B–7378

To release the parking brake push down on the bottom (heel) of the pedal [C].

C

B–3744 B–5717

–5–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

STEERING LEVERS

A

1

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

W–2046–0595 B–7379

The steering levers (Item 1) [A] are on the right and left side in front of the seat.

B

FORWARD BACKWARD

For safe control of the loader always move the levers slowly and smoothly. Only a small movement is necessary to move the loader.

The steering levers control forward and reverse travel of the loader [B].

FORWARD TRAVEL – Push both levers forward.

REVERSE TRAVEL – Pull both levers backward.

NORMAL TURNING – Move one lever farther forward than the other.

FAST TURNING – Push one lever forward and pull the other lever backward.

LEFT TURN

RIGHT TURN

LEFT FAST TURN

RIGHT FAST TURN

For slow travel speed, push the steering levers forward only a small amount.

To increase travel speed, push both levers farther forward.

For maximum pushing force, push the levers forward only a small amount with the engine at full RPM.

PI–1849

–6–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS

A

Foot Pedals

3

Keep both feet on pedals while operating machine. Failure to do so can cause serious injury.

2

1

4

5

W–2002–1285

Put your feet on the pedals and KEEP THEM THERE any time you operate the loader.

B–5723

Two foot pedals (Item 1) [A] control the hydraulic cylinders for the lift and tilt functions.

B

Lift Arm Operation The left pedal controls the lift arms. Push on the bottom (heel) (Item 2) [A] of the pedal to raise the lift arms.

Push on the top (toe) (Item 3) [A] of the pedal to lower the lift arms.

1

Tilt Operation (Bucket) The right pedal controls the action of the bucket. Push the top (toe) (Item 4) [A] of the pedal to tilt the bucket forward.

Push the bottom (heel) (Item 5) [A] of the pedal to tilt the bucket backward.

Lift Arm Float Position

B–7379

Use the float position of the lift arms to level loose material while driving backward. (See Leveling the Ground, Page 21.) In this position, there is no hydraulic force on the lift arms so the bucket is held down only by gravity.

C

Push the top (toe) (Item 3) [A] of the left pedal all the way forward until the pedal is in the locked position (detent).

A–2408

A–2409

AVOID BURNS Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments. Be careful when connecting and disconnecting quick couplers.

W–2220–0396

Auxiliary Lever Operation (Optional on 642B) The right steering lever is also the control lever for the auxiliary hydraulics [B]. (Refer to Page 65 for lock bolt removal.)

1

Move the steering lever to the left or to the right to activate the auxiliary hydraulics and operate an attachment [C].

(Example: To open or close grapple teeth.)

Move the lever in the opposite direction to reverse the action of the attachment.

Move the steering lever all the way to the right (Item 1) [B] to put the control valve into the detent position for a constant flow of hydraulic fluid under pressure to the quick couplers.

B–7379

–7–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

DAILY INSPECTION

A

The loader must be in good operating condition [A].

Check the following items before starting each day: • Engine Oil • Hydraulic/Hydrostatic Fluid • Engine Cooling System • Air Cleaner System • Operator Cab, Seat Belt, Seat Bar & Pedal Interlocks • Lift Arm & Cylinder Pivot Pins • Tires & Tire Pressure • Any Loose or Broken Parts • Safety Tread & Machine Signs

B–6583

Follow the maintenance requirements on the Service Schedule Decal, located inside the rear door [B].

Fluids such as engine oil, hydraulic fluid, coolants, etc. must be disposed of in an environmentally safe manner.

Some regulations require that certain spills and leaks on the ground must be cleaned in a specific manner. See local, state and federal regulations for correct disposal.

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manuals, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death [A].

W–2003–1289

B

6567875

–8–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM

A

The seat bar restraint system has a pivoting seat bar (Item 1) [A] with arm rests and has spring loaded interlocks for the lift and tilt control pedals. The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat. The interlocks require the operator to lower the seat bar in order to operate the foot pedal controls. When the seat bar is up, the lift and tilt control pedals are locked when returned to the neutral position.

1

P–1718

AVOID INJURY OR DEATH

When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

W–2046–0592

B

SEAT BAR DOWN

The spring loaded interlocks (Item 1) [B] control the locking and unlocking functions of the control pedals.

2

Seat Bar

The interlocks (Item 1) [B] require the operator to lower the seat bar (Item 2) [B] which allows the operator to move the foot pedals to control the lift and tilt functions.

When the seat bar is lowered, it pushes the interlock (Item 1) [B] down on both sides, releasing the pedal linkages (Item 3) [B] from the interlocks.

Pedal Linkage

The pedals will pivot in both directions when the interlock is down.

3

1 Interlock

Interlock Shield

MC–1668

AVOID INJURY OR DEATH

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

C

SEAT BAR RAISED Seat Bar

W–2045–1086

AVOID INJURY OR DEATH The seat bar system must lock the lift and tilt control pedals in neutral when the seat bar is up. Service the system if pedals do not lock correctly.

Interlock

W–2105–1285

Interlock Shield

When the seat bar is raised, spring forces raise the interlocks [C].

The foot pedals will not pivot when the interlock is up.

Refer to the Preventive Maintenance section for Seat Bar Restraint System Inspection & Maintenance. (See Page 31.)

MC–1668

–9–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

GETTING READY FOR OPERATION

A

Read the Operation & Maintenance Manual and the Operator’s Handbook before operating the loader [A].

6569119

Operator must have instructions before running the machine. Untrained operators can cause injury or death.

W–2001–1285

B–7377

Getting On and Off the Loader

B

Use the bucket or attachment steps, grab handles and safety treads (on top of the loader lift arms and frame) to get on and off the loader [B].

Safety treads are installed on the Bobcat loader to provide a slip resistant surface for getting on and off the loader.

Keep safety treads clean and replace when damaged.

Replacement treads are available from your loader dealer.

B–3943

C

Adjust the seat position for comfortable operation of the loader controls.

Fasten the seat belt snugly and adjust it so that the buckle is centered between the hips [C].

C–2596

C–2621 C–2637

D

Lower the seat bar [D].

Be sure the parking brake is engaged.

C–2621 C–2623

–10–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

GETTING READY FOR OPERATION (Cont’d)

A

Getting On and Off the Loader (Cont’d) All controls must be in the neutral position before you start the engine. (See Starting The Engine, Page 12.)

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

C–2621 C–2624

B

W–2046–0595

Keep your hands on the steering levers and feet on the pedals while seated in the loader [A].

Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can cause an explosion or fire.

B–6586

W–2063–0887

Always fill the fuel tank after the engine has cooled. The area must have good ventilation and be free of sparks or open flames. NO SMOKING! [B].

Machine Signs (Decals) Follow the instructions on all the machine signs (decals) that are on the loader. Replace any damaged machine signs and be sure they are in the correct locations (See Pages xiv & xv). Machine signs are available from your dealer.

–11–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE

A

WRONG

When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside.

Exhaust fumes contain odorless, invisible gases which can kill without warning.

W–2050–1285 B–3724

B

WRONG

AVOID INJURY OR DEATH • Engines can have hot parts and hot exhaust gas. Keep flammable material away.

• Do not use machines in atmosphere containing explosive gas.

W–2051–1086 B–6578

Normal Starting Condition

C

Adjust the seat position for comfortable operation of the foot pedals and steering levers.

Fasten the seat belt snugly and adjust it so the buckle is centered between your hips.

Lower the seat bar [C].

B–6579

–12–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Normal Starting Condition (Cont’d)

NEUTRAL POSITION

Put the foot pedals and steering levers in neutral (center) position (Item 1) [A].

Set the engine speed control to the half speed position (Item 2) [A].

1 1/2 ENGINE SPEED

643 Only: The engine stop control must be pushed down.

Turn the key to the ON position. The engine and transmission warning lights must be ON when the key is ON and the engine is stopped (Item 3) [A].

2 ON POSITION

Do not use ether with glow plug (preheat) systems. Explosion can result which can cause injury or death.

3

W–2071–1285

PREHEAT POSITION (641, 643 Only)

641 & 643 Only: Turn the key to the left to the PREHEAT position (Item 4) [A].

Refer to the decal located on the right side of the operator cab for operation of the preheat (glow plugs) system [B].

4 START POSITION

Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Cool the starter for one minute between uses.

5 ON (RUN) POSITION

I–2034–0284

Turn the key to the start position (Item 5) [A] and release it when the engine starts. Do not run the starter more than 15 seconds.

6

When the engine starts, release the key and it will return to the run position (Item 6) [A]. The warning lights must go off.

PI–2188

B

STOP THE ENGINE IF THE WARNING LIGHTS DO NOT GO OFF and correct the problem.

6565927

–13–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Cold Temperature Starting Condition If the temperature is below 32°F (0°C), use the following procedure to make starting the engine easier:

1

1. Use engine oil with the correct type and viscosity for the anticipated starting temperature. (See Oil Chart on Page 38.)

2. Make sure the battery is at full charge.

3. Install a block heater or tank heater on the engine.

4. 642 & 642B Only: Pull up on the choke control (Item 1) [A].

B–9409

5. Follow the steps under Normal Starting Condition and repeat the PREHEATING procedure until the engine starts.

6. 642 & 642B Only: Push the choke control down as the engine begins to run smoothly.

When the temperature is below –20°F (–30°C), hydrostatic oil must be warmed before starting.

The hydrostatic system will not get enough oil at low temperatures and will be damaged. Park the machine in an area where the temperature will be above 0°F (–18°C) if possible.

I–2007–1285

Let the engine run for a few minutes to warm the engine and the hydrostatic oil before operating the loader.

During very cold temperatures, (0°F (–23°C) and below), let the engine run longer than five (5) minutes.

NOTE: If the transmission warning light comes on while operating the loader, more warm–up time is needed.

–14–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS

A

WRONG

Never use attachments or buckets which are not approved by Melroe Company. Buckets and attachments for safe loads of specified densities are approved for each model.

Unapproved attachments can cause injury or death.

W–2052–1285 B–6587

The dealer can identify, for each model loader, the attachments and buckets approved by Melroe Company.

The buckets and attachments are approved for Rated Operating Capacity and for secure fastening to the Bob–Tach.

A

WEIGHT OF LOADS LBS. (KG)

The Rated Operating Capacity for this loader is shown on a label in the operator cab. (See Specifications, Page 81.)

It is determined by using a standard dirt bucket, and material of normal density, such as dirt or dry gravel. If longer buckets are used and load center moves forward and reduces the Rated Operating Capacity. If very dense material is loaded, the volume must be reduced.

Exceeding the Rated Operating Capacity [A] can cause the following problems: 1. Steering the loader may be difficult.

2. Tires may wear faster.

3. There will be a loss of stability.

5 (127)

4. The life of the Bobcat loader will be reduced.

22 (559)

Use the correct size bucket for the type and density of material being handled. For safe handling of materials and avoiding machine damage, the attachment (or bucket) should handle a full load without going over the Rated Operating Capacity for the loader. Partial loads make steering more difficult.

34 (864) CENTER OF LOAD LOCATION Inches (mm) 600 SERIES MODELS

Maximum loads to be carried when using a pallet fork are shown in figure [B].

6558413

Installation and Removal (641, 642, 643) (Optional on 642B) The loader is equipped with the Bob–Tach system. The Bob–Tach is used for fast changing of buckets and attachments. See the Installation Instructions to install other attachments.

AVOID INJURY OR DEATH Do not exceed rated operating capacity.

Excessive load can cause tipping or loss of control.

W–2053–0887

–15–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS (Cont’d)

A

Installation and Removal (641, 642, 643) (Optional on 642B) (Cont’d)

Bob–Tach levers have spring tension. Hold lever tightly and release slowly. Failure to obey warning can cause injury.

W–2054–1285

PI–2590 B–3851

Pull the Bob–Tach levers all the way up.

B

Tilt the Bob–Tach forward. Drive the loader forward until the top edge of the Bob–Tach is completely under the flange of the bucket [A].

DO NOT hit the Bob–Tach levers on the bucket.

Tilt the Bob–Tach backward until the bucket is off the ground and stop the engine [B].

PI–2591 B–3850

AVOID INJURY OR DEATH Before you leave the operator’s seat:

C

• Lower the lift arms, put the attachment flat

on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

W–2045–1086

To lock the Bob–Tach wedges push down on the levers as shown [C].

B–3852 B–7018

D

Bob–Tach wedges must extend through the holes in attachment. Levers must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death.

W–2102–0588

The wedges (Item 1) [D] must extend through the holes (Item 2) [D] in the attachment.

1

NOTE: The Bob–Tach system is optional on the 642B. See Page 17 for bucket attachment procedure on the 642B.

2 B–3893

–16–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS (Cont’d)

A

Installation of Attachment (642B Standard) This standard Bobcat loader is equipped with the Bob–Tach frame only. No locking levers or wedges are supplied. The buckets and attachments are bolted onto the Bob–Tach frame. The installation procedure for the buckets is given here. Other attachments mount with the same procedure.

Installation of Bucket (642B) Install the bucket using the following procedure: Tilt the Bob–Tach frame forward. Drive forward to the bucket until the top edge of the Bob–Tach frame is under the flange of the bucket and centered [A].

B–9624

B

Tilt the Bob–Tach frame backward until the bucket is lifted off the ground and stop the engine.

AVOID INJURY OR DEATH Before you leave the operator’s seat:

• Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

B–9626

C

W–2045–1086

Mark the bucket through the holes (one on each side) [B].

Remove the bucket from the Bob–Tach frame.

Drill a 5/8’’ (16mm) hole in the bucket where marked.

Install the bucket on the Bob–Tach frame and install the bolt [C].

B–9627

Never use attachments or buckets which are not approved by Melroe Company. Buckets and attachments for safe loads of specified densities are approved for each model.

Unapproved attachments can cause injury or death.

D

W–2052–1285

Install the nut on the bolt and tighten to 125–140 ft.–lbs.

(170–190 Nm) torque.

Removal of Bucket (642B) Fully lower the lift arms and tilt the Bob–Tach frame forward so that the front of the bucket is just above the ground. Stop the engine.

Remove the bolts.

B–9649

–17–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES

A

When operating on a public road or highway, always follow local regulations. For example: Slow Moving Vehicle Sign or Directional Signals may be required.

WITH BUCKET FULL

Always warm the engine and hydrostatic system before operating the loader.

Going Up Slope

Machines warmed up with moderate engine speed and light load have longer life.

I–2015–0284

B

B–6612

WITH BUCKET FULL

Operate the loader with the engine at full RPM for maximum horsepower. Move the steering levers only a small amount to operate the loader slowly.

New operators must operate the loader in an open area without bystanders.

Operate the controls until the loader can be handled at an efficient and safe rate for all conditions of the work area.

Fill the bucket to the Rated Operating Capacity. The loader will turn better with a full load (Rated Operating Capacity) than with just part of a load.

Going Down Slope

With a full bucket, go up or down the slope with the heavy end toward the top of the slope [A] & [B].

C

With empty bucket, go down or up the slope with the heavy end toward the top of the slope [C] & [D].

B–6612

WITH BUCKET EMPTY

AVOID INJURY OR DEATH • Keep the lift arms as low as possible.

• Do not travel or turn with the lift arms up.

• Turn on level ground.

• Go up and down slopes, not across them.

• Keep the heavy end of the machine uphill.

• Do not overload the machine.

Going Down Slope

D

Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

B–6611

WITH BUCKET EMPTY

W–2018–1187

Raise the bucket only high enough to avoid obstructions on rough ground.

Going Up Slope

–18–

B–6611

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES (Cont’d)

A

Filling the Bucket Push down on the top of the lift pedal until the lift arms are all the way down. Push the top of the tilt pedal to put the cutting edge of the bucket on the ground [A].

B–12106

B–6719

Drive slowly forward into the material. Push the bottom of the tilt pedal to raise the front of the bucket [B].

B

B–12106

Load, unload and turn on flat level ground. Do not exceed rated operating capacity shown on sign (decal) in cab. Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

W–2056–1187

Drive backward away from the material.

B–6718

Emptying the Bucket

C

Push down on the bottom (heel) of the lift pedal to raise the bucket over the truck box or bin [C].

Drive forward slowly until the bucket is over the top of the truck box or bin. Push the top of the tilt pedals until the bucket is empty [C]. If all the material is near the side of the truck or bin, push it to the other side with the bucket.

B–12106

Never dump over an obstruction, such as a post, that can enter the operator cab. The machine could tip forward and cause injury or death.

W–2057–0694 B–6708

–19–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES (Cont’d)

A

Digging Into the Ground Put the lift arms all the way down. Push the top (toe) of the tilt pedal until the cutting edge of the bucket is on the ground.

B–12106

Drive forward slowly and continue to tilt the bucket down until it enters the ground [A].

B–6720

Push the bottom (heel) of the tilt pedal a small amount to increase traction and keep an even digging depth [B].

B

Continue to drive forward until the bucket is full. When the ground is hard, raise and lower the cutting edge of the bucket with the tilt pedal while driving forward slowly.

B–12106

B–6721

C

Push the bottom (heel) of the tilt pedal to tilt the bucket backward as far as it will go when the bucket is full [C].

B–12106

B–6717

–20–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES (Cont’d)

A

Leveling the Ground (Using Lift Arms in Float Position) Push the top (toe) of the lift pedal all the way forward until the pedal is in the locked position (detent) to put the lift arms in a float position [A].

B–12106

Push the tilt pedal to change the position of the cutting edge on the bucket. With the bucket tilted farther forward, there is more force on the cutting edge and more loose material can be moved.

Never drive forward when the hydraulic control for lift arms is in float position.

B–6722

I–2005–1285

B

Drive backward to level loose material. Push the bottom (heel) of the lift pedal to unlock from the detent position.

Backfilling Lower the lift arms and put the cutting edge of the bucket on the ground. Drive forward to the edge of the hole to push the material into the hole [B].

B–12106

Tilt the bucket forward as soon as it is past the edge of the hole [B].

If necessary, raise the lift arms to empty the bucket.

B–6724

–21–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

PARKING THE BOBCAT LOADER

A

AVOID INJURY OR DEATH Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

B–12105

W–2045–1086

Stop the Bobcat loader on level ground.

Lower the lift arms fully and put the attachment flat on the ground.

641, 642 & 642B: Pull the engine speed control all the way backward. Turn the key switch to the OFF position.

643 Only: Pull the engine speed control all the way backward and pull up on the engine stop control. Push the stop control in when the engine has stopped and turn the key to the OFF position.

Engage the parking brake.

Lift the seat bar and make sure the foot pedals are in the locked position.

Unbuckle the seat belt. Remove the key from the switch to prevent operation of the loader by unauthorized personnel.

STOPPING THE BOBCAT LOADER When the steering levers are moved to the neutral position, the hydrostatic transmission will act as a service brake and stop the loader.

TRANSPORTING THE BOBCAT LOADER

Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

W–2058–0494

A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [A].

Be sure the transport and towing vehicles are of adequate size and capacity.

–22–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

TRANSPORTING THE BOBCAT LOADER (Cont’d)

A

Use the following procedure to secure the Bobcat loader to the transport vehicle [A]: Lower the bucket or attachment to the floor and stop the engine.

Engage the parking brake.

Install chains at the front as shown and to the rear to prevent the loader from moving during sudden stops or when going up and down slopes.

TOWING THE BOBCAT LOADER

C–2563

B–7384

Never attempt to start the engine by pushing or pulling. Hydrostatic pumps and motors will be damaged.

I–2001–1285

To prevent damage to the loaders hydrostatic system, the loader must be towed only a short distance at slow speed.

(Example: Moving the loader onto a transport vehicle).

The towing chain (or cable) must be rated at 1–1/2 times the weight of the loader. (See Specifications, Page 81.)

B–7383

If the engine will not start or the hydrostatic system is not working correctly, the loader can be pulled only when a towing tool is installed. The towing tool is available from your Bobcat loader dealer.

Do not push or pull the machine at more than 2 MPH (3,2 km/h) or for a distance of more than 25 feet (7,6 meters) with the towing tool in place.

I–2017–0389

–23–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

LIFTING THE BOBCAT LOADER

A

641,642,642B,643Operation&MaintenanceManual#6570241–OperatingInstructionsSection

1

1

AVOID INJURY OR DEATH • Before lifting, check fasteners on single point lift and operator cab.

• Assemble front cab fasteners as shown in manual.

• Never allow riders in the cab or bystanders

within 15 feet (5 meters) while lifting the machine.

W–2007–0694

The loader can be lifted with the single point lift which is available as a kit from your Bobcat loader dealer.

Fasten the pins (Item 1) [A] in the kit as shown.

The single point lift, supplied by Melroe Company is designed to lift and support the Bobcat loader without affecting roll over and falling object protection features of the operator cab.

B–7489

–24–

641, 642, 642B & 643 Bobcat Loader Operation & Maintenance Manual

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Adjusting the Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 & 44 AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 BRAKE PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Cleaning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Checking the Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 & 41 Removing Coolant from the Cooling System . . . . . . . . . . . . . . . . . . . . 41 & 42 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Removing and Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Servicing the Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Using An Extra Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Replacement of Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 FINAL DRIVE TRANSMISSION (Chaincase) . . . . . . . . . . . . . . . . . . . . . . . . . . 61 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Removing Air from the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 GOVERNOR (642 & 642B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Governor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 HYDRAULIC/HYDROSTATIC FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . 58 HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hydraulic/Hydrostatic Fluid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Hydraulic/Hydrostatic Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 LUBRICATION OF THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . 63 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Lowering the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Raising the Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Adjusting the Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Opening the Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Inspecting the Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Maintaining the Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Cab Wiring Diagram (Three Piece Instrument Panel) . . . . . . . . . . . . . . . . . 46 Cab Wiring Diagram (One Piece Instrument Panel) . . . . . . . . . . . . . . 47 & 48 Engine Wiring Diagram (641) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Engine Wiring Diagram (642) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Engine Wiring Diagram (643) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Engine Wiring Diagram (642B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 –25–

PREVENTIVE MAINTENANCE

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

MAINTENANCE SAFETY Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

W–2003–0797 Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

CORRECT

CORRECT

B–10731

B–12365

B–7469

Never service the Bobcat® Skid Steer Loader without instructions.

Use the correct procedure to lift or lower operator cab with lift arms down.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B–11799

B–3724

B–6593

Have good ventilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

Vent exhaust to outside when engine must be run for service.

Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device.

Never modify equipment or add attachments not approved by Melroe Company.

WRONG

WRONG

WRONG

B–6590

B–6580

B–6589

Stop, cool and clean engine of flammable materials before checking fluids.

Never service or adjust loader with the engine running unless instructed to do so in the manual.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes.

Never fill fuel tank with engine running, while smoking or when near open flame.

Keep body, jewelry and clothing away from moving parts, electrical contacts, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding.

Keep rear door closed except for service. Close and latch door before operating the loader.

Lead–acid batteries produce flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on contact.

Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts.

–26–

MSW01–0498

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader.

Instructions are necessary before operating or servicing machine.

Read Operation Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manual when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

W–2003–1289

ITEM Engine Oil Engine Air Cleaner (641 & 643) Engine Cooling System Tires Seat Belt and Seat Bar Safety Signs (Decals) Safety Tread Lift Arm and Bob–Tach Pivot Areas Engine Fuel Filter (641 & 643) Operator Cab Wheel Nuts Engine Oil and Filter Battery Parking Brake Hydraulic Fluid, Tubelines and Hoses Alternator Drive Belt Chaincase Controls Spark Arrestor Muffler Engine Air Cleaner (642B) Governor (642 & 642B) Seat Bar Steering Shaft Pivots Hyd. and Hydro. Filters Ignition System (642) U–Joint Engine Fuel Filter Hydraulic/Hydrostatic Reservoir Breather Cap Chaincase Hydraulic Fluid Reservoir

SERVICE REQUIRED

8–10

50

100 250 500 1000

Check the oil level & add oil as needed.

Empty the dust cup. Check for leaks and damaged components.

Replace the outer filter element only when the red ring shows in the indicator window.

Clean debris from shrouds & grills. Check coolant level in the recovery tank and add as needed.

Check for damaged tires and correct air pressure.

Check the condition of seat belt. Check the seat bar for correct operation.

Check for damaged signs (decals) and safety treads. Replace any signs and safety treads that are damaged or worn.

Add grease to the fittings until extra grease shows.

Remove water from filter.

Check the fastening bolts, washers and nuts. Check the condition of the cab.

Check for loose wheel nuts. Tighten to correct torque if loose.

Replace the oil and the engine oil filter.

Check the water level. Check battery cables for corrosion. Check that the battery cables are tight. Check covers.

Check operation and adjust as needed.

Check the fluid level and add as needed. Check for damage and leaks and replace as needed.

Check the tension and adjust as needed.

Check the fluid level and add as needed.

Check operation and adjust as needed.

Remove the plug and clean the spark chamber.

Replace air condition element. Replace element more often when operating in severe dust conditions.

Check oil level and add as needed.

Grease pivots as needed.

Grease two (2) fittings. Add oil to steering shaft.

Replace filter elements.

Check plugs, points and timing. Replace damaged parts.

Grease three (3) fittings with correct grease.

Replace the filter element.

Replace breather cap.

Replace the fluid.

Replace the hydraulic fluid.

Check wheel nut torque every 8 hours for the first 24 hours.

Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ON. Or every 12 months.

–27–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

LIFT ARM SUPPORT DEVICE

A

NOTE: Lift arm support devices are available from your Bobcat loader dealer.

Never work on a machine with the lift arms up unless the lift arms are secured by a lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.

W–2059–0991

Maintenance and service work can be done with the lift arms lowered. If the lift arms must be raised for service, use the following procedure:

B–6581

Place jackstands under the rear corners of the loader.

One person must be in the operator’s seat, with the seat belt fastened and the seat bar lowered, until the lift arm support device is installed [A].

Start the engine and raise the lift arms all the way up.

Have a second person install the lift arm support device over the rod of one of the lift cylinders.

The lift arm support device must be tight against the cylinder rod. Lower the lift arms slowly until the support device is held between the lift arm and the lift cylinder.

–28–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

OPERATOR CAB

A

The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects.

Nut ROPS

Plate Washer Vibration Dampner

Check with your dealer if the operator cab has been damaged.

Fender

Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Melroe Company.

Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

Washer

MC–1181 C–2599

W–2069–1285

The operator cab fastening bolts and nuts must be tight [A].

Tighten to 40–50 ft.–lbs. (54–68 Nm) torque.

Both sets of fasteners at the front of the operator cab (ROPS) must be assembled as shown in this manual. Failure to secure ROPS correctly can cause injury or death.

W–2005–1189

Raising the Operator Cab

Before the cab or the lift arms are raised for service, jackstands must be put under the rear corners of the frame. Failure to use jackstands may allow the machine to tip backward causing injury or death.

W–2014–1285

Stop the loader on a level surface. Lower the lift arms fully.

If the lift arms must be up while raising the operator cab, install a lift arm support device. (See Page 28.)

Remove the two (2) fasteners (including the washers or plates) at the front corners of the operator cab [A].

–29–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

OPERATOR CAB (Cont’d)

A

Raising the Operator Cab (Cont’d) If the lift arms are down, stand on the safety tread (lift arm crossmember) and lift on the top of the operator cab and the grab handle. Slowly lift until the operator cab is all the way up [A].

B–7465

If the lift arms are up, install an approved lift arm support device. (See Page 28.) Stand in front of the loader. Lift on the grab handle and the bottom of the operator cab slowly until the operator cab is all the way up [B].

B

Lowering the Operator Cab NOTE: Make sure the seat bar is fully raised or lowered when lowering the cab. Always use the grab handles to lower the cab.

If the lift arms are down, stand on the safety tread (lift arm crossmember). Pull down on the bottom of the operator cab and use the grab handles and the operator cab top until the operator cab is all the way down [A].

If the lift arms are held up by a lift arm support device, stand in front of the loader. Pull down on the bottom of the operator cab and use the grab handle until the cab is all the way down [B].

B–7463

Install the two (2) fasteners, (including the washers and plate). Tighten the nuts to 40–50 ft.–lbs. (54–69 Nm) torque [C].

C

Nut ROPS

Plate Washer Vibration Dampner

Fender

Washer

MC–1181 C–2599

–30–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM

A

The seat bar restraint system has a pivoting seat bar (Item 1) [A] with arm rests and has spring loaded interlocks for the lift and tilt control pedals. The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat. The interlocks require the operator to lower the seat bar in order to operate the foot pedal controls. When the seat bar is up, the lift and tilt control pedals are locked when returned to the neutral position.

1

P–1718

Inspecting the Seat Bar

B

Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Operate each foot pedal to check both the lift and tilt functions. Raise the lift arms until the bucket is about 2 feet (600 mm) off the ground.

Raise the seat bar. Try to move each foot pedal. Pedals must be firmly locked in neutral position. There must be no motion of the lift arms or tilt (bucket) when the pedals are pushed.

Clean & Lubricate

Pull the seat bar down, lower the lift arms. Operate the lift pedals. While the lift arms are going up, raise the seat bar and the lift arms should stop.

B–7387

Lower the seat bar, lower the lift arms and place the bucket flat on the ground. Stop the engine. Raise the seat bar and operate the foot pedals to be sure that the pedals are firmly locked in the neutral position. Unbuckle the seat belt.

C

Maintaining the Seat Bar See the Service Schedule Page 27 and on the loader for correct service interval.

Clean any debris or dirt from the moving parts [A] & [B].

Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm).

Use general purpose grease to lubricate the seat bar pivot points at each side of the cab [A].

B–9781

If the seat bar system does not function correctly, check for free movement of each linkage part. Check for excessive wear. Adjust pedal control linkages. Replace parts that are worn or damaged. Use only genuine Melroe replacement parts.

–31–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

REAR DOOR

A

Opening the Rear Door

AVOID INJURY Never service or adjust the machine when the engine is running unless instructed to do so in the manual.

W–2012–0290

B–3853

Open the rear door to service the engine. Pull the door latch up and to the left to release the door latch [A].

B

1

The door can then be opened to get to the engine.

2

Keep the rear door closed when operating the machine. Failure to do so could seriously injure a bystander.

3

W–2020–1285 B–7385 B–5772

Adjusting the Rear Door

C

Loosen the set screw (Item 1) [B].

Loosen the nut (Item 2) [B].

1

2

Turn the bolt (Item 3) [B] in or out, until the door contacts both the top and bottom of the loader frame (Item 1) [C] with the lever in the latched position.

3

NOTE: It takes approximately 50 lbs. (22 kg) of force to push the lever down when the latch is adjusted correctly.

With the set screw up, the flanges at the bolts (Item 3) [C] must be to the sides so that the set screw aligns with the flat surface of the end of the bolt.

1

B–7226 B–4099

Tighten the set screw (Item 1) [B].

Tighten the nut (Item 2) [B] to 65–70 ft.–lbs. (88–95 Nm) torque [B].

–32–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

AIR CLEANER SERVICE

A

See the Service Schedule Page 27 for the interval to service the air cleaner system.

641

Check the air intake hoses for wear. Check if the air cleaner is damaged. Check all the connections.

1

B–7444

B

641 & 643DS Only: Replace the large (outer) filter element only when the red ring shows in the window of the condition indicator [A] & [B].

641 & 643 Only: Replace the inner filter every third time the outer filter is replaced or when the red ring still shows in the indicator window after the outer filter has been replaced.

643

1

B–7386

C

642 Only: Replace the filter element only when the red ring shows in the window of the condition indicator [C].

NOTE: Before replacing the filter element, push the button on the condition indicator (Item 1) [A], [B] and [C], start the engine. If the red ring does not show, do not replace the filter element.

642

1

B–7449

642B Only: Replace the filter element every 100 hours as the service schedule requires. Replace more often when operating in severe dust conditions.

D

642B

NOTE: There is no condition indicator on the 642B [D].

B–9618

–33–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

AIR CLEANER SERVICE (Cont’d)

A

Use the following procedure to replace the filter element(s):

641 & 643 * 5

Loosen the clamp (Item 1) [A] & [B] on the dust cup.

2

Remove the dust cup (Item 6) [A] & [B] and the outer element (Item 2) [A] & [B].

Remove the rubber boot (Item 3) [A] & [B] inside the dust cup and empty the dust cup.

6

Clean the inside of the air cleaner housing so the element has a smooth surface to contact at the seal (Item 4) [A] & [B].

Check the air cleaner housing for holes from corrosion.

5

Install the new filter element(s).

3

1

*Inner Element

NOTE: The washer (Item 5) [A] & [B] must be under the wing nut.

D–1535

Install the dust cup so the arrow on the cup is up. Tighten the clamp.

B

642 & 642B

Push the button on the indicator to remove the red ring.

2 5

4

1 3

6

C–1024

C

Record the operating hours of the loader on the decal (Item 1) [C] inside the rear door.

1

B–7388

–34–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

FUEL SYSTEM

A

Fuel Specifications 641 & 643 Only: Use number 2 diesel fuel in the engine.

During very cold temperatures, number 1 fuel can be used.

641 & 643

1

The following is one suggested blending guideline which should prevent fuel gelling problems: Temp. F° (C°)

No. 2

No.1

+15° (9°) Down to –20° (–29°) Below –20° (29°)

100% 50% 0%

0% 50% 100%

We recommend an operator contact their fuel supplier for local recommendations.

642 Only: Use regular gasoline in the engine.

642B Only: Use regular or unleaded gasoline in the engine.

B–3854

Filling the Fuel Tank

B

642 & 642B 1

Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can cause an explosion or fire.

W–2063–0887

Remove the fuel fill cap (Item 1) [A] & [B].

B–3994

Use a clean, approved safety container to add fuel of the correct specifications. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING! [C].

C

WRONG

Install and tighten the fuel fill cap [A].

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285

B–6586

–35–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

FUEL SYSTEM (Cont’d)

A

Fuel Filter (641 & 643 Only)

641

The fuel filter is on the right upright in the engine compartment [A] & [B].

2

See the Service Schedule Page 27 for the interval to service the fuel filter.

If there is water in the water trap at the bottom of the filter, loosen the thumb screw (Item 1) [A] & [B].

3

Remove the water trap and clean the water from the trap.

Use the following procedure to replace the fuel filter element:

1

Clean the fuel filter area. Close the shut–off valve.

B–3959

B

Use a wrench to loosen the fuel filter head bolts (Item 2) [A] & [B]. Remove the water trap and filter element.

643

Replace seals as needed.

2

Installation: Install the new filter element and water trap and hand tighten only.

Open the shut–off valve (Item 2) [C].

3

Fuel Filter (642 & 642B Only)

1

The fuel filter (Item 1) [C] is in the fuel line by the shut–off valve (Item 2) [C].

B–3916

See the Service Schedule Page 27 for the interval to service the fuel filter.

C

Clean the area around the fuel filter. Close the shut–off valve (Item 2) [C].

642 & 642B

Loosen the nut and remove the tubeline (Item 3) [C].

Remove the element from the valve.

1

Install a new element with the arrow pointing in the direction of the carburetor.

3

Connect the tubeline and tighten the nut. Open the valve.

Start the engine and check for leaks.

2 B–3994

Record the operating hours of the loader on the decal inside the rear door.

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285

–36–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

FUEL SYSTEM (Cont’d)

A

Removing Air from the Fuel System (641)

1 2

After replacing the fuel filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system before to starting the engine.

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes causing serious injury. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention.

B–2249 B–7445

B

W–2074–1285

1 Open the rear door. The engine must be cool.

Loosen the slotted plug (Item 1) [A].

Move the priming lever (Item 2) [A] until fuel flows from the plug (Item 1) [A] with no air bubbles showing.

Tighten the vent plug.

Loosen the pressure fitting at each injector (Item 1) [B].

B–7444

Turn the engine until the fuel flows from the fittings with no air bubbles.

C

Tighten the fitting. Do not overtighten.

2

Removing Air from the Fuel System (643)

1

After replacing the fuel filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine.

Open the rear door. The engine must be cool.

Open the vent plug (Item 1) [C].

Operate the hand pump (Item 2) [C] until fuel flows from the vent plug (Item 1) [C] with no air bubbles.

B–3916

Tighten the vent plug.

D

Operate the hand pump until it feels solid.

1

Move the throttle control to minimum RPM. Loosen the valve (Item 1) [D] and squeeze the hand pump several times.

Start the engine. When the engine runs smoothly, close the valve (Item 1) [D].

B–3597

–37–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM

641

A

Checking Engine Oil

3

1

Check the engine oil level every day.

Before starting the engine for the work shift, open the rear door. Remove the dipstick (Item 1) [A], [B], [C] & [D].

2 B–7445

B

642

2 1

B–7450

C

Keep the oil level between the marks on the dipstick [C].

643

Use a good quality motor oil that meets API Service Classification of CD or better (See Oil Chart below).

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE) C° –34

–29

–23

–18

–13

–7

1

+4

+10

+15

+21

+27

+32

Keep Oil Level Between These Marks

1

+38

SAE 10W–30/40

SAE 15W–40

SAE 5W–30

A–1528 B–6658 SAE 30W

2

SAE 10W

F° –30

–20

–10

0

+10

+20

+30

642B

D

SAE 20W–20

+40

+50

+60

+70

+80

+90

1

+100

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (GASOLINE: USE API CLASSIFICATION SE or SF) (DIESEL: USE API CLASSIFICATION CC or CD)

B–9622

–38–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM (Cont’d)

A

Replacement of Oil and Filter

641

See the Service Schedule Page 27 for the service interval for replacing the engine oil and filter.

Operate the engine for about 15 minutes. Stop and engine. Lift the front of the loader about 6 inches and block it.

Open the drain (Item 1) [A], [B], [C], and [D].

Remove the filter (Item 2) [A] (Page 38), (Item 2) [B], (Item 3) [C], or (Item 2) [D].

1

Clean the filter housing surface. Put clean oil on the gasket of the new filter and install the filter and hand tighten only.

B–3965

B

Close the drain. Remove the oil filler cap (Item 3) [A] (Page 38) or (Item 2) [B] (Page 38), (Item 2) [C], or (Item 2) [D] (Page 38). Fill to capacity. (See Specifications, Page 81.)

642 2

1

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

B–4260

W–2103–1285

C

643

Start the engine and let it run for about 5 minutes. Stop the engine. Check for leaks at the filter. Check the oil level. Add oil until the level is at the FULL mark on the dipstick. Install the oil filler cap.

2 NOTE: DO NOT overfill the crankcase.

Record the operating hours of the loader on the decal inside the rear door.

1

3

B–3600

B–3597

D

642B

1 2

B–9633

–39–

B–9628

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

COOLING SYSTEM

A

Check the cooling system every day to prevent overheating, loss of performance or engine damage.

Keep the rear grill area free from debris or overheating will result [A].

Wear safety glasses to prevent eye injury when any of the following conditions exist:

B–9650

• When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

B

W–2019–1285

642

Cleaning the Cooling System Open the rear door.

1

Open the access panel at the top of the blower housing.

Remove the grill.

Use air pressure or water pressure to remove the debris in the area of the radiator and oil cooler.

B–7451

If debris is a problem, check with your dealer about the special debris screens.

C

Checking the Coolant Level

643

642, 643, 642B Only Check the cooling system regularly to prevent overheating, loss of performance or engine damage.

1

The coolant recovery tank (Item 1) [B], [C], and [D] must be at the FULL COLD mark when engine is cool.

Fill the radiator with premixed coolant.

Drain, flush and refill system with correct premixed coolant whenever coolant becomes discolored.

B–6603

ETHYLENE GLYCOL – Mix 50% water and 50% ethylene glycol.

D

PROPYLENE GLYCOL – Mix 47% water and 53% propylene glycol.

642B 1

These mixtures will provide freeze protection to –34°F (–37°C).

Do not mix ethylene glycol and propylene glycol.

B–9641

–40–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

COOLING SYSTEM (Cont’d)

A

Checking the Coolant Level (Cont’d)

641

641 Only

1

The engine is air–cooled and must have good air circulation to operate correctly.

Keep all shrouding in place and free of dents.

Clean debris from the grill and the cooling fins, or overheating will result.

2

To clean the cooling fins, remove the blower housing cover (Item 1) [A]. Use an air hose to remove debris from the cylinder heads and the blower fan (Item 2) [A].

B–7444

Check the radiator cap (Item 1) [B] for correct pressure rating or overheating can result.

B

Check for leaks in the cooling system. Check for worn or damaged hoses, clamps or radiator. Check for loose or worn water pump belt.

Replace damaged parts immediately to prevent leaks and overheating.

1

Removing Coolant from the Cooling System B–12038

C

642B

Do not remove radiator cap when the engine is hot. You can be seriously burned.

W–2070–1285

642B Only To remove the coolant from the engine, use the following procedure: Lift the grill [A]. (See Page 40.)

B–9901

Remove the radiator cap (Item 1) [B].

D

Remove radiator hose [C].

642B

Drain coolant into a container [D].

B–9960

–41–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

COOLING SYSTEM (Cont’d)

A

641,642,642B,643Operation&MaintenanceManual#6570241–PreventiveMaintenanceSectionPart1of2

Removing Coolant from the Cooling System (Cont’d)

642

1 Do not remove radiator cap when the engine is hot. You can be seriously burned.

W–2070–1285

B–7452

642 Only: Remove the plug (Item 1) [A] and install a fitting in the hole. Connect a hose to the fitting. Drain the coolant into a container.

B

643 Only: Connect a hose to the valve or use a funnel to keep coolant from getting into the engine compartment.

Open the valve (Item 1) [B] and drain coolant into a container.

642 Only: When all the coolant is removed, disconnect the fitting from the hole. Install and tighten the plug.

643

1

643 Only: Turn the lever (Item 1) [A] on the valve. When all the coolant is removed, close the valve.

Fill the radiator with premixed coolant and install the radiator cap.

Install the grill. Fill the coolant recovery tank 1/3 full with premixed coolant. (See Checking the Coolant Level, Page 40.)

B–3599

–42–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

ALTERNATOR BELT

A

Adjusting the Alternator Belt

641

641 & 643 Stop the engine.

5/16 (7,94 mm)

Raise the operator cab. (See Page 29.)

Remove the belt shield.

Loosen both the adjustment bolts (Item 1) [A] or [B] and move the alternator to set the belt tension at 5/16” (8 mm) movement between pulleys with 15 pounds (67 N) of force. Tighten the adjustment bolt (Item 1) [A] or [B].

1 B–7445

Install the belt shield.

B 643

1 5/16 (7,94 mm)

2

B–7466

C

642 Stop the engine.

642

Remove the belt shield [C].

B–12104

Loosen the governor adjustment bolts (Item 1) [D]. Use a bar and adjust belt tension to 1/2” movement at the middle of the belt with 20 lbs. (89 N) pressure. Tighten the bolts.

D 642

Loosen the alternator adjustment bolts (Items 2 & 3) [D].

Move the alternator until there is 1/4” movement at the middle of the belt with 20 lbs. (89 N) pressure. Tighten the bolts.

1 1/2” Freeplay (13 mm)

1/4” Freeplay (6,5 mm)

2

3

B–2661

–43–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

ALTERNATOR BELT (Cont’d)

A

Adjusting the Alternator Belt (Cont’d)

642B

642B To adjust the belt tension, use the following procedure: 1. Stop the engine.

2. Remove the belt shield [A].

B–9640

3. Loosen the bolts that mount the governor [B].

B

Move the governor until the belt tension permits 1/4” movement at the middle of the belt with 20 lbs. (89 N) of force. Tighten the bolts.

642B

B–9637

4. Loosen the bolts that mount the alternator [C].

C

Move the alternator until the belt has 3/8” movement at the middle of the belt with 22 lbs. (98 N) of force.

Tighten the bolts [A].

642B

B–9639

–44–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

GOVERNOR (642 & 642B)

A

Rod Adjustment

642

To adjust the governor linkage, use the following procedure: 1. Stop the engine.

3

2

2. Loosen the screws (Item 1) [A] or [B] on the governor arm.

3. Hold the governor arm in the closed position.

Tighten the screws.

1 B–6936 B–2320

Install the belt shield before starting the engine.

B

642B

1

Governor Oil Level Check the oil level in the governor after every 100 hours of operation. Use the following procedure:

3 2

Remove the check plug (Item 2) [A] or [B] at the rear of governor.

If oil flows out the hole, the level is good.

If no oil flows out the hole, remove the fill plug (Item 3) [A] or [B] at the top of the governor and add SAE 10W–30 or 10W–40 until oil flows from the check plug hole. Install the plug and tighten.

B–9638

–45–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

CAB WIRING DIAGRAM (Three Piece Instrument Panel) 641 (S/N 20847 & Above) 642B (Optional) (S/N 27321 & Above) 643 (S/N 22556 & Above)

6720033

–46–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

CAB WIRING DIAGRAM (One Piece Instrument Panel) 642B Standard Cab (S/N 27351 & Above)

6720126

–47–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

CAB WIRING DIAGRAM (One Piece Instrument Panel) 641 (S/N 20001 – 20846) 642 (S/N 20001 & Above) 642B Deluxe Cab (S/N 27230 & Below) 642B Standard Cab (S/N 27350 & Below) 643 (S/N 20001 – 20555)

6566807

–48–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

ENGINE WIRING DIAGRAM (641) *641 (S/N 13001 – 20408) Delco Alternator 641 (S/N 20409 & Above) Melroe Alternator

6566809

–49–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

ENGINE WIRING DIAGRAM (642) *642 (S/N 13083 – 20840) Delco Alternator

6566810

–50–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

ENGINE WIRING DIAGRAM (643) *643 (S/N 13001 – 21230) Delco Alternator 643 (S/N 21231 & Above) Melroe Alternator

6566811

–51–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

ENGINE WIRING DIAGRAM (642B) 642B (S/N 25001 & Above)

6570267

–52–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM

A

Description The loader has a 12 volt, negative ground alternator charging system. The electrical system is protected by fuses located in the engine compartment. The fuses will protect the electrical system when there is an electrical overload. The reason for the overload must be found before starting the engine again.

Servicing the Electrical System If the fuses become damaged, replace them with the same type and size fuses (25 Amp.).

The battery cables must be clean and tight. Check the water level in the battery. Remove any acid or corrosion from the battery and cables with a sodium bicarbonate and water solution cover the battery terminals and cable ends with grease [A].

A–2741

Check for broken wires or loose connections.

NOTE: The warning lights (on the instrument panel) will come ON, when the the key switch is turned ON. When the engine is started, the warning lights must go OFF. If they do not, stop the engine and find the problem.

Using An Extra Battery (Jump Starting)

Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame.

Do not jump start or charge a frozen battery.

Warm battery to 60°F. (16°C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.

Battery gas can explode and cause serious injury.

W–2066–0490

B

641

If it is necessary to use an extra battery to start the engine, BE CAREFUL! There must be one person in the operator’s seat and one person to connect and disconnect the battery cables [B].

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water for several minutes and get medical attention in case of eye contact.

W–2065–1286

B–12727

–53–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Using An Extra Battery (Jump Starting) (Cont’d)

642B

Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame.

Do not jump start or charge a frozen battery.

Warm battery to 60°F. (16°C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.

Battery gas can explode and cause serious injury.

B–9645 B–9646

W–2066–0490

If it is necessary to use a booster battery to start the engine, BE CAREFUL! There must be one person in the operator’s seat and one person to connect and disconnect the battery cables.

B

642

The key switch must be in the OFF position. The booster battery to be used must be 12 volt.

Connect the end of the first cable to the positive (+) terminal of the booster battery. Connect the other end of the same cable to the starter [A], [B], [C], & [B] (Page 53).

Connect the end of the second cable to the negative (–) terminal of the booster battery. Connect the other end of the second cable to the engine [A], [B], [C], & [B] (Page 53).

Keep cables away from moving parts. Start the engine.

(See Starting The Engine, Page 12.)

After the engine has started, remove the cable connected to the engine ground (–) cable first.

B–9408 B–9407

Remove the cable connected to the starter.

C

643

Damage to the alternator can occur if:

• Engine is operated with battery cables disconnected.

• Battery cables are connected when using a

fast charger or when welding on the loader (Remove both cables from the battery).

• Extra battery cables (booster cables) are connected wrong.

I–2023–1285

B–12047 B–12048

–54–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Removing and Installing the Battery

Damage to the alternator can occur if:

• Engine is operated with battery cables disconnected.

• Battery cables are connected when using a

fast charger or when welding on the loader (Remove both cables from the battery).

• Extra battery cables (booster cables) are connected wrong.

B–3709

641

B

I–2023–1285

1

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water for several minutes and get medical attention in case of eye contact.

B–7445

W–2065–1286

C

642

643

Open the rear door. Disconnect the negative (–) battery cable [A].

Disconnect the positive (+) battery cable.

Remove the battery holddown clamp (Item 1) [B], [C] and [D].

Remove the battery from the loader.

1 1 B–6603 B–7451

D

642B

1 B–9616

–55–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Removing and Installing the Battery (Cont’d) Clean the terminals on the new battery [A] & [B].

Install the new battery, the holddown clamps and the terminal covers.

NOTE: DO NOT touch any metal with the battery terminals.

Install and tighten the battery cables. Connect the ground (negative) cable last to prevent sparks.

B–3707

B

B–3707

–56–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

SPARK ARRESTOR MUFFLER

642B

A

See the Service Schedule Page 27 for service interval for cleaning the spark arrestor muffler.

Do not operate the loader with a defective exhaust system.

1

This loader is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler. It is necessary to do maintenance on this spark arrestor muffler to keep it in working condition. The spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation.

B–9636

B

If this machine is operated on flammable forest, brush or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442 PRC.

642 & 643

1

Make reference to local laws and regulations for spark arrestor requirements.

I–2022–1285

Stop the engine. Open the rear door.

B–4038

Remove the plug (Item 1) [A], [B], & [C] from the bottom of the muffler.

C

641

1 When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside.

Exhaust fumes contain odorless, invisible gases which can kill without warning.

W–2050–1285

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety glasses or goggles. Failure to obey can cause serious injury.

B–4100

W–2011–1285

Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.

W–2068–1285

When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death.

Start the engine and run for about 10 seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler.

W–2006–0284

Stop the engine. Install and tighten the plug.

Close the rear door.

–57–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC FLOW CHART 641 (Starting With S/N 13209) 642 (Starting With S/N 13524) 642B (Starting With S/N 25000) 643 (Starting With S/N 13406)

6570287 6570266

–58–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM

A

The hydraulic and hydrostatic systems use the same hydraulic fluid reservoir.

The system has an engine driven implement pump that supplies fluid to the control valve and lift and tilt cylinders.

Fluid also goes from the control valve to the hydrostatic transmission pumps to provide charge pressure and cooling.

1

A #3 element filter and the hydraulic filter clean the fluid and protect the system from contamination.

The oil cooler is located above the radiator. The oil cooler is used for cooling the hydraulic fluid before it returns to the hydraulic pump.

B–5733

B

Hydraulic/Hydrostatic Fluid Reservoir Use only recommended fluid in the hydraulic system.

(See the Specifications Section for the correct fluid.)

Checking and Adding Fluid To check the fluid reservoir, use the following procedure: Put the Bobcat loader on a level surface. Lower the lift arms and tilt the Bob–Tach fully backward. Stop the engine.

Check the fluid level shown in the sight gauge (Item 1) [A].

B–9647

Hydraulic fluid must show in the sight gauge. If the fluid is not seen in the sight gauge, remove the filler cap from the reservoir. Add fluid to the reservoir until it shows in the sight gauge. Replace the filler cap [B].

C

Hydraulic/Hydrostatic Fluid Replacement See the Service Schedule Page 27 for the service interval. The fluid must be replaced if it becomes contaminated or after major repairs.

Remove the fill cap and lift the screen from the tank [C].

Check the screen for damage. Wash the screen in clean solvent.

B–9673

Remove the fluid from the reservoir with a hydraulic transfer pump or a hand operated suction pump [D].

D

B–5834

–59–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Hydraulic/Hydrostatic Fluid Replacement (Cont’d)

641

Install the screen and cap.

Replace the #3 element filter and the hydraulic filter.

Add fluid to the reservoir until the fluid shows in the sight gauge. DO NOT fill above the top mark of the sight gauge [A]. (See Page 59.)

1

B–7446

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes causing serious injury. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention.

B 642 1

W–2074–1285

Start the engine and operate the hydraulic controls.

Check for leaks and add oil as necessary.

Hydraulic/Hydrostatic Filter Replacement See the Service Schedule Page 27 for the service interval. The filter must be replaced when the hydrostatic warning light comes on during loader operation.

B–7451

C

Remove the filter element (Item 1) [A], [B], [C] & [D].

Drain fluid into a container.

643

Clean the surface of the filter head where the element contacts the head.

1

Put clean oil on the rubber gasket of the filter element.

B–6603

Install the filter element hand tight only [D].

D 642B

1

B–9643

–60–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Hydraulic/Hydrostatic Filter Replacement (Cont’d)

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

B–7388

W–2103–1285

B

Check for leaks after operating the loader.

Record the operating hours of the loader on the decal inside the rear door [A].

FINAL DRIVE TRANSMISSION (Chaincase) The chaincase contains the final drive sprockets and the chains and is filled with the same type of fluid as the hydraulic/hydrostatic system. (See Specifications Page 81.)

1

To check the chaincase, use the following procedure: C–2037

Put the Bobcat loader on a level surface.

Remove the plug at the front of the transmission housing (Item 1) [B]. If oil can be reached with the tip of your finger through the hole, the oil level is correct.

If the level is low, add oil through the check plug hole until the oil flows from the hole. Install and tighten the plug.

–61–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

TIRE MAINTENANCE

A

Check the tires regularly for wear, damage and pressure.

(See Specifications, Page 81 for the correct tire pressure.)

Tire Rotation Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to the rear and rear tires to the front [A].

It is important to keep the same size tires on each side of the loader. If different sizes are used, each tire will be turning at a different rate and cause excessive wear. The tread bars of all the tires must face the same direction.

C–1965

Do not inflate tires above specified pressure.

Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death.

W–2078–1285

Tire Mounting Tires are to be repaired only by an authorized person using the proper procedures and safety equipment. Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage.

The rim flange must be cleaned and free of rust. The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire, avoid excessive pressure which can rupture the tire and cause serious injury or death. During inflation of the tire, check the tire pressure frequently to avoid over inflation.

Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability.

Wheel Nuts See the Service Schedule Page 27 for the service interval to check the wheel nuts. The correct torque is 105–115 ft.–lbs. (142–156 Nm) for 9/16” wheel nuts and 65–70 ft.–lbs. (88–95 Nm) for 1/2” wheel nuts.

Inflate tires to the MAXIMUM pressure shown on the sidewall of the tire. DO NOT mix brands of tires used on the same loader.

I–2057–0794

–62–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

LUBRICATION OF THE BOBCAT LOADER

HYDRAULIC RESERVOIR

A

Lubricate the Bobcat loader as specified in the Service Schedule Page 27 for the best performance [A].

CHAINCASE

Always use good quality lithium based multipurpose grease when you lubricate the Bobcat loader. Apply lubricant until extra grease shows.

COOLANT

GREASE

TRANSMISSION OIL FILTER GREASE

6567875

B

Lubricate the seat rails with oil for easy movement.

See the Service Schedule Page 27 for service interval to grease the U–joints.

Grease the universal joints (Item 1) [B] and spline with special U–joint lubricant. See your dealer.

1

B–3371

Lubricate the mounting (pivot assemblies) of the seat bar [C].

C

B–7387

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641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

LUBRICATION OF THE BOBCAT LOADER (Cont’d)

A

Raise the operator cab. (Refer to Page 29 for the correct procedure.) Grease the pivot bearings [A]. (See the Service Schedule Page 27 for the correct service interval.)

B–5191

B–5197

B

Add oil or grease as needed to the steering control shaft [B].

B–12728

BOB–TACH

C

Check for free movement of wedges and Bob–Tach levers.

The wedges must extend far enough to engage the holes in the attachment [C].

Bob–Tach wedges must extend through the holes in attachment. Levers must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death.

B–3893

W–2102–0588

Replace wedges that are bent or broken.

–64–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

AUXILIARY CONTROL LOCKBOLT

A

The auxiliary control has a lockbolt that must be removed to use the auxiliary hydraulics.

Raise the operator cab. (See Page 29 for the correct procedure.)

Remove the nut and bolt at the right hand steering lever [A].

B–5731

PIVOT PINS

B

All pivot pins, lift arms, Bob–Tach and cylinders have a large pin held in position with lockbolts [B].

B–3858

C

BRAKE PEDAL ADJUSTMENT Loosen the lock nut (Item 1) [C] and turn the nut on the linkage rod (Item 2) [C] to adjust the brake pedal.

There must be 1/4” (6,35 mm) of movement under the bottom edge (heel) of the brake pedal.

Tighten the jam nut when the adjustment is correct.

B–6707

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TROUBLESHOOTING TROUBLESHOOTING THE DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 70 TROUBLESHOOTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 TROUBLESHOOTING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . 71

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TROUBLESHOOTING The following information identifies loader problems which can occur most often. Service procedures for correcting loader problems can be found in this manual on the pages indicated. Some procedures are marked D/S (Dealer Service) and must be performed only by qualified Bobcat service personnel.

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manuals, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

W–2003–1289

TROUBLESHOOTING THE ENGINE PROBLEM Engine won’t turn over with starter.

CAUSE

CORRECTION

PAGE

Battery has low charge.

Charge battery and find cause of discharge.

–

Cables loose or dirty.

Clean and tighten the battery cables.

54

Check the starting circuit. Repair as needed.

D/S

Wrong starting procedure.

Use correct starting procedure.

12

Ignition system is damaged.

Check & repair as needed.

D/S

Auxiliary control lever or lift pedal is in detent.

Take out of detent.

7&8

No fuel in tank.

Add fuel.

35

Vent in fuel filler cap is plugged.

Clean the vent.

–

Dirt or water in fuel system.

Repair as needed.

D/S

Fuel filter is dirty.

Install a new filter.

36

Hole in fuel line.

Repair as needed.

–

Weak battery.

Charge or replace battery.

55

Wrong oil in engine.

See Oil Specifications.

38

Cylinder compression is low.

Recondition the engine.

D/S

Engine has overheated.

Check cooling system.

40

Poor fuel quality.

Use fresh, good quality fuel.

35

Restricted exhaust.

Clean exhaust system.

57

Dirt, water or air in fuel system.

Clean and repair as needed.

D/S

Damaged wiring.

Engine turns with starter, but is difficult to start.

Engine has little power or runs rough.

starter,

solenoid

or

D/S = Dealer Service Only

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641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

TROUBLESHOOTING THE ENGINE (Cont’d) PROBLEM

CAUSE

Engine has little power or runs rough (Cont’d).

Engine overheats.

CORRECTION

PAGE

Engine is hot.

See Engine Overheats

–

Restricted exhaust.

Clean exhaust system

57

Dirty air cleaner

Install new element.

33

Cylinder compression is low.

Recondition the engine.

D/S

Restriction in cooling air flow.

Check for debris on radiator grill.

–

Check shroud and repair or replace as needed.

–

Run at full throttle.

–

Blower shroud missing.

damaged

or

Engine is overheated.

TROUBLESHOOTING THE DRIVE SYSTEM PROBLEM

CAUSE

No drive on both sides.

Hydraulic fluid is low.

Check oil level. Add as needed.

59

Damaged hydraulic pump.

Check condition of pump and replace as needed.

D/S

Hydrostatic system is damaged.

Check hydrostatic system.

D/S

Control linkage is disconnected.

Repair linkage.

D/S

Hydrostatic system is damaged.

Check hydrostatic system and make repair as needed.

D/S

Wrong tire pressure.

Check all tires for correct pressure.

62

Steering linkage interference.

Check steering linkage and adjust as needed.

D/S

Damaged hydrostatic system.

Check system. Repair as needed.

D/S

Machine moves when levers are in neutral.

Steering linkage out of adjustment.

Adjust steering linkage.

D/S

System is overheating.

Hydraulic oil level is low.

Check oil level and add as needed.

59

Clean cooling system. Check for debris on radiator grill.

–

Check by–pass valve.

D/S

Auxiliary control in detent.

Take out of detent.

7&8

Loader is overloaded.

Use correct size attachment.

15

Hydrostatic transmission damage.

Check system and make repair.

D/S

Out of adjustment.

Adjust parking brake.

65

No drive on one side.

Machine pulls to one side.

Cooling system restricted.

is

Low charge (transmission light on).

Parking brake will not hold.

CORRECTION

dirty.

Air

pressure

PAGE

D/S = Dealer Service Only –70–

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

TROUBLESHOOTING THE HYDRAULIC SYSTEM PROBLEM No hydraulic action.

Hydraulic action is rough.

Hydraulic action is slow.

Hydraulic cylinders leak oil.

CAUSE

CORRECTION

PAGE

No hydraulic oil.

Check oil level and add as needed.

59

Pedals are disconnected.

Check linkage. Repair as needed.

–

Relief valve is damaged.

Replace the relief valve.

D/S

Hydraulic pump is damaged.

Check pump. Replace as needed.

D/S

Hydraulic oil is too thick.

Let machine warm up.

12

Hydraulic oil level is low.

Check oil level and add as needed.

59

Air is in the oil.

Cycle the hydraulics.

–

Pedal is hitting floor or debris under pedal.

Check debris.

Remove

–

Cylinders leak internally.

Check condition of cylinders and repair as needed.

D/S

Hydraulic pump is damaged.

Check pump. Replace as needed.

D/S

Control valve is damaged.

Check valve and repair as needed.

D/S

Hydraulic oil is too thick.

Let machine warm up.

12

Damage to cylinder rods or seals.

Repair cylinders.

D/S

adjustment.

D/S = Dealer Service Only

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MACHINE SIGN TRANSLATIONS IMPORTANT (6560573) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 SERVICE SCHEDULE (6567875) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 WARNING (6579511) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 WARNING (6579510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 WARNIING (6579528, 6579639, 6579509) . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

MACHINE SIGN TRANSLATIONS

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IMPORTANTE (SPANISH) ESTA MAQUINA ESTA EQUIPADA POR LA FABRICA CON UN AMORTIGUADOR DE CHISPAS DEL SILENCIADOR, APROBADO POR EL SERVICIO DE SILVICULTURA DEL U.S.D.A. (DEPARTMENTO DE AGRICULTURA DE LOS ESTADOS UNIDOS).

ES NECESARIO LIMPIAR ESTE AMORTIGUADOR DE CHISPAS DEL SILENCIADOR PARA MANTENERLO EN BUEN ESTADO. HAY QUE DARLE SERVICIO AL AMORTIGUADOR, VACIANDO LA CAMARA DE CHISPAS CADA 100 HORAS DE FUNCIONAMIENTO. SI ESTA MAQUINA ESTA DESTINADA PARA TRABAJAR EN BOSQUES, MATORRALES O EN PASTOS QUE PUEDAN INCENDIARSE, ENTONCES TIENE QUE ESTAR EQUIPADA CON UN AMORTIGUADOR DE CHISPAS EN EL SISTEMA DEL ESCAPE Y TIENE QUE MANTENERSE EN PERFECTAS CONDICIONES DE TRABAJO. ES NO HACER ESTO CONSTITUYE UNA INFRACCION DE LA LEY ESTATAL DE CALIFORNIA, SECCION 4442, PRC. REFIERASE A LAS LEYES Y REGULACIONES LOCALES EN CUANTO A LOS REQUISITOS DEL AMORTIGUADOR DE CHISPAS.

IMPORTANT (FRENCH) CETTE CHARGEUSE EST EQUIPPEE A LA SORTIE DE L’USINE D’UN SILENCIEUX PARA–ETINCELLES APPROUVE PAR LE SERVICE DES EAUX ET FORETS DES ETATS–UNIS. IL EST INDISPENSABLE D’EFFECTUER UN ENTRETIEN REGULIER DE CE PARE–ETINCELLES AFIN DE LE GARDER EN BON ETAT DE MARCHE. L’ENTRETIEN CONSISTE A VIDER LA CHAMBRE A ETINCELLES TOUTES LES 100 HEURES DE MARCHE. SI CET ENGIN EST UTILISE SUR UN TERRAIN COUVERT D’ARBRES, DE BROUSSAILLES, OU D’HERBAGES INFLAMMABLES, IL FAUT INSTALLER LE PARE–ETINCELLES ET LE GARDER EN BON ETAT DE MARCHE. CONSULTER LES APPLICABLES.

REGLEMENTATIONS

LOCALES

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ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTE

• Mantenga le puerta cerrada excepto para dar servicio.

• Mantenga el motor limpio y que no tenga material inflamable.

• Mantenga el cuerpo. objetos sueltos y la ropa lejos de los conductores eléctricos, piezas móviles, piezas calientes y del escape.

• No use el cargador en lugares donde

hay polvo o gases explosivos o materiales inflamables cerca al escape.

• Todos los gases del escape pueden matar. Ventile siempre el lugar de trabajo.

• No use nunca éter o líquido del arranque en los motores

• Les liquides sous pression peuvent pénétrer au travers de

• Escapes de líquido bajo presión pueden penetrat en la

• L’acide des batteries provoque de graves brûlures, porter

• El ácido de la batería puede causar quemaduras severas,

• Les batteries dégagent des gaz inflammables et

de diesel que tienen tapones encendedores. Use solamente las ayudas para el arranque que sean aprobados por el fabricante del motor.

piel y causar heridas graves. Se requiere atención médica inmediata. Use gafas. Use cartón para revisar si hay fugas. use gafas. Si el ácido hace contacto con los ojos, la piel o la ropa, lávelos bién con agua. Si el contactor fuel en los ojos, lávelo bién y vaya al médico.

• Las baterias producen gas inflammable y explosivo.

la peau et causer de graves blessures. Consulter immédiatement un médecin Porter des lunettes de sécurité. Utiliser du carton pour repérer les fuites. des lunettes de sécurité. S’il entre en contact avec les yeux, la peau ou les vêtements, rincer généreusement à l’eau. Pour les yeux, appeler un médecin.

explosifs. Tenir les arcs électriques les étincelles, les flammes et las cigarettes allumées à l’écart.

• En cas de démarrage par pontage, effectuer le dernier

Mantenga lejos, arcos, chispas, llamas y tabaco encendido.

branchement (Câble négatif) au moteur (jamais à la batterie). Pour débrancher, déconnecter d’abord le câble négatif du moteur.

• Para arranque con batería auxiliar, conecte de último el

• Ne jamais utiliser d’éther ou de liquide de démarrage sur

cable negativo al motor del cargador (nunca la batería).

Despues de hacer el arranque con cables, quite peimero la conección negativa del motor.

un moteur diesel avec des bougies de préchauffage.

N’employer que les aides au démarrage approuvées par le fabricant.

AVERTISSEMENT (FRENCH) EVITER LES BLESSURES, VOIRE LA MORT

• Maintenir la porte arrière fermée, sauf pour les entretiens.

• Débarasser le moteur de toute matière inflammable.

• Maintenir le corps, les objets non attachés et les vêtements à l’écart des contacts électriques, des pièces mobiles et brûlantes et de l’échappement.

• Ne pas utiliser la machine dans un endroit chargé de poussières ou de gaz explosifs, et où l’échappement risque de toucher des matériaux inflammables.

• Les gaz d’échappement peuvent être mortels. Toujours aérer.

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9. Cinturon/barra del asiento y enclavamientos de los pedales

PROGRAMA DE SERVICIO (SPANISH) CADA 10 HORAS 1. Aceite del Motor–Verifique el nivel–no lo llene demasiado (Consulte el Manual del Operario para ver cual fluido recominenda).

2. Filtro del Aire del Motor–(Vacie la tapa recolectora de polvo y cambie el elemento si es necesario).

3. Sistema de Enfriamiento del Motor–Limpiar la basura de las aletas de enfriamiento de la guardera y del enrejado. Verifique en frio el nivel del líquido enfriador, agregue etilenglicol y agua en las cantidades necesarias para obtener una proporción de 50% a 50% de cada uno.

4. Verifique las correas del ventilador y de la bomba para asegurase qu están en buenas condiciones y que la tensión está bién.

5. Brazos de Elecación y Puntos de Pivote del Cilindro – Lubríquelos con grasa de base be litio para uso multiple.

6. Neumáticos – Verifique la persión de aire.

FLOTATION – 35 PSI (241 kPa) STANDARD Y CLASIFICACION DE 8 PLIEGOS – 50 PSI (340 kPa), 5.70 x 12 – 40 PSI (275 kPa). Verifique que no tengan cortadas.

7. Sistema de Aire del Motor – Verifique que no haya escapes ni componentes dañados.

8. En General – Verifique que no haya piezas ni sueltas ni rotas, qu no estén dañados ni el cinturón de seguridad ni la cabina del operador. Verifique tembién el funcionamiento de los instrumentos, que no haya tuercas sueltas en las quedas, escapes de aceite, etc.

–77–

– Comprobar su funcionaminento. Reparar o cambiar si es necessario. Eliminar la suciedad en las piezas moviles.

10. Filtro del Combustible – Purgue el agua atrapada (solamente para diesel).

CADA 50 HORAS 1. Fluido Hidráulico – Verifique el nivel del fluído.

Consulte el Manual del Operador para ver vual fluído recomendado.

2. Caja de la Cadena – Verifique el nivel del fluído.

Consulte el Manual del Operador para ver cual fluído recomendado.

3. Batería – Verifique su condición.

4. Controles y Frenos – Verifique el funcionamiento.

Hacer ajustes si es necesario.

CADA 100 HORAS 1. Sistema de Encendido – Verificar las bujias, los platinos y la sincronización–cambie las piezas defectuosas (solamente para gasolina).

2. Silenciador con Amortiguador de Chispas – Vasie la cámara de chispas.

3. Sistema Hidráulico – Cambie el filtro – modelos 440, 540.

4. Aceite del Motor – Drenarlo mientras está caliente y cambiar el filtro (en las cargadoras 440 solamente se cambia el aceite cada 25 horas). consulte el Manual del Operador para ver cual fluído recomendado.

CADA 250 HORAS 1. Sistema Hydraulico – Cambie el filtro en el model 843.

2. Filtro Final del Combustible – Reemplace el elemento del filtro.

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

3. Linea Motriz – Engrase la uniones universales con una grasa aprobada según la recomendación del Manual de Servicio.

4. Engrase el pivote de la barra del asiento en cuanto sea necesario.

5. Cojinetes de la dirección – Lubricar con grasa al litio de uso general.

6. Aplicar aceite o grasa al árbol.

7. Filtro hidrostático (sólo máquinas 640, 740 y 843) – Sustituir el elemento filtrante. Sustituirlo también si el piloto de aviso de la transmisión del salpicardero está encendido y permanece así durante cinco (5) minutos después de que el líquido hidrostático haya alcanzado la temperatura de trabajo.

CADA 500 HORAS 1. Sistema Hidráulico – Cambie el filtro de brone si está equipado con este.

2. Filtro Primario del Combustible – Limpie el cubo de sedimento.

3. Reemplace la tapa del respiradero del depósito hidráulico.

CADA 1000 HORAS 1. Depósito Hidráulico–Drenar el fluído y reemplazarlo.

Consulte el Manual del Operador para ver cual fluído recomendados.

2. Caja de la Cadena–Drene el fluído y reemplazarlo.

Consulte el Manual del Operador para ver cual fluído recomendado.

PROGRAMME D’ENTRETIEN (FRENCH) TOUTES LES 10 HEURES 1. Huile de moteur–Vérifier le niveau – ne pas remplir à rasbord (conseiller le manuel d’utilisation pour le fluide recommandé).

2. Filtre à air du moteur (vider la capsule à poussiere changer l’élément si nécessaire).

3. Système de refroidissement du moteur – nettoyer les débris de ailettes de refroidissement, coucliers et grilles. – Vérifier le niveau de température de liquide de refroidissement, ajouter 50–50 d’éthylène glycol et eau autant que nécessaire.

4. Vérifier la condition et la tension du ventilateur et des courroies de transmission de la pompe.

5. Levier du chargeur et les points de pivot du cylindre – graisser avec une huile multi–usage à base de lithium.

6. Pneus – vérifier le gonflement: FLOTATION – 35 PSI (241 kPa), STANDARD et 8 PLY – 50 PSI (340 kPa), 5.70 x 12 – 40 PSI (275 kPa); vérifier l’état des pneus (entailles).

7. Système d’aération du moteur – contrôler les fuites et les éléments abimés.

8. Conseils géneraus: vérifier les pièces abimées ou ayant du jeu, centinure de sécurité abimée et cabine de l’utilisateur, instrument de commande, écrous devissés des roues, fuites d’huile, etc.

9. Ceinture de sécurité/arceau de siège et verrouillage des

TOUTES LES 100 HEURES 1. Système d’allumage – vérifier les bougies régler l’allumage, remplaer les pièces défectueuses (essence seulement).

2. Pot d’echappement – vider la chambre à étincelles.

3. Système hydraulique – changer le filtre (des modèles 440 et 540).

4. Huile de moteur – vider chaud et changer le filtre (huile de remplacement seulement, toutes les 25 heures pour chargeur 440). Voir le manual d’utilisation en ce qui concerne l’huile recommendée.

TOUTES LES 250 HEURES 1. Système hydraulique – changer le filtre sur le 843.

2. Dernier filtre à essence – remplacer la pièce du filtre.

3. Arber de transmission – graisser le joint U avec un lubrifiant approivé par le manuel.

4. Graisser le pivot du siège autant que nécesaire.

5. Bagues de direction – lubrifier avec une graisse tous usages à base de lithium.

6. Levier de direction – ajouter de l’huile ou de la graisse à l’arbre.

7. Filtre hydrostatique – séries 640, 740 et 843 uniquement) – remplacer l’élément de filtre.

Remplacez–le aussi si le témoin de transmission au tableau de bord s’allume et reste allumé pendant cinq (5) minutes après que l’huile hydrostatique ait atteint sa température de fonctionnement.

TOUTES LES 500 HEURES 1. Système hydraulique – remplacer le filtre bronze si le système en est équipé.

2. Premier filtre à essence – nettoyer le récipiente à seidments.

3. Remplacer le bouchon – filtre du réservoir hydraulique.

TOUTES LES 1000 HEURES 1. Réservoir hydraulique – vider le fluide et le remplacer.

Voir manuel d’utilisation pour le fluide recommendé.

2. Boîte à chaînes – vider le fluide et le remplacer par celui conseillé par le manual d’utilisation.

pédales – Vérifiez le fonctionnement. Remplacez ou réparez si nécessaire. Eliminez les saletés et les débris de pièces mobiles.

10. Filtre du carburante – retirer l’eau qui s’y trouve (diesel seulement).

TOUTES LES 50 HEURES 1. Fluide hydraulique – vérifier le niveau du fluide. Voir le manuel d’utilisation pour le fluide recommendé.

2. Boíte à chaines – vérifier le niveau du fluide.

Consulter le manuel d’utilisation en ce qui concerne le fluide recommendé.

3. Batterie – vérifier l’etat.

4. Commandes et freins – vérifier l’etat de marche, régler si nécessaire.

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ADVERTENCIA (SPANISH)

ATTENTION (FRENCH)

EVITE HERIDAS O LA MUERTE

EVITER LES BLESSURES OU LA MORT

NO USE NUNCA EL CARGADOR SIN LEER LAS INSTRUCCIONES. LEA EL MANUAL DEL OPERATIO, EL MANUAL DE SERVICIO Y LA GIA DEL OPERARIO.

NE JAMAIS SE SERVIR DE LA CHARGEUSE SANS INSTRUCTIONS. LIRE LE MANUEL DE L’OPERATEUR EL D’ENTRETIEN AINSI QUE LE GUIDE D’UTILISATION.

NO VIAJE O DE LA VUELTA CON LOS BRAZOS DE ELEVACION ARRIBA. CARGUE, DESCARGUE Y DE LA VUELTA ESTANDO EN UN SITIO PLANO Y NIVELADO. NO EXCEDA LA CAPACIDAD NOMINAL DE FUNCIONAMIENTO (VEA EL AVISO EN EL CARGADOR).

NE PAS SE DEPLACER NI VIRER AVEC LE BRAS RELEVES. CHARGER, DECHARGER ET VIRER SUR UN SOL PLAT ET HORIZONTAL. NE PAS DEPASSER LE CAPACITE NOMINALE (CONSULTER L’AUTOCOLLANT APPOSE SUR LA CARGEUSE).

USE LA BARRA DEL ASIENTO. ASEGURESE BIEN EL CINTURON DE SEGURIDAD.

UTILISER L’ARCEAU DE SECURITE. ATTACHER SOIGNEUSEMENT LA CEINTURE DE SECURITE.

NUNCA MODIFIQUE EL EQUIPO NI USE ADITAMENTOS QUE NO ESTEN APROBADOS POR LA COMPAÑIA MELROE.

NE JAMAIS MODIFIER L’EQUIPEMENT NI SE SERVIR D’ACCESSOIRES QUE NE SONT PAS APPROUVES PAR MELROE COMPANY.

MANTENGA LOS PIES EN LOS PEDALES. MAINTENIR LES PIEDS SUR LES PEDALES. EN LA PENDIENTES, MANTENGA EL EXTREMO PESADO DE CARGADOR EN POSICION ASCENDENTE. ANTES DE BAJARSE DEL CARGADOR 1. BAJE LOS BRAZOS DE ELEVACION. COLOQUE EL ADITAMENTO BEIN EN EL SUELO.

DANS LES PENTES, TOUJOURS MAINTENIR LA PARTIE LA PLUS LOURDE DE LA CHARGEUSE VERS LE HAUT. POUR QUITTER LA CHARGEUSE: 1. ABAISSER LES BRAS DE LEVAGE. POSER L’EQUIPEMENT A PLATE SUR LE SOL.

2. PARE EL MOTOR 2. ARRETER LE MOTEUR. 3. PONGA EL FRENO. 3. ENCLENCHER LE FREIN DE STATIONNEMENT. 4. LEVANTE LA BARRA DEL ASIENTO. MUEVA LOS PEDALES HASTA QUE AMBOS SE TRABEN.

–79–

4. RELEVER L’ARCEAU DE SECURITE. DEPLACER LES PEDALES JUSQU’A CE QU’ELLES SOIENTE TOUTES DEUX VERROILLEES. 641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

641,642,642B,643Operation&MaintenanceManual#6570241–MachineSignTranslationsSection

ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTE LLEVE LA CARGA EN POSICION BAJA EL NO OBEDECER ESTA ADVERTENCIA PUEDE CAUSAR LADEAMIENTO O VUELCOS O PERDIDAD DE LA CARGA Y DE LA VISIBILIDAD.

PELIGRO (SPANISH) EVITE LA MUERTE

• MANTENGASE RETIRADO DE ESTA AREA CUANDO

AVERTISSEMENT (FRENCH)

LOS BRAZOS DE ELEVACION ESTAN ELEVADOS, A MENOS QUE ESTEN TRABADOS POW EL TOPE. • EL MOVER EL PIE DEL PEDAL O FALLA DE UNA PIEZA PUEDEN CAUSAR LA CAIDA DE LOS BRAZOS DE ELEVACION.

EVITER DES BLESSURES OU LA MORT TENIR LA CHARGE VERS LE BAS. LE NON RESPECT PEUT ENTRAINER UN BASCULEMENT OU UN RENVERSEMENT DE LA MACHINE, UNE PERTE DE LA CHARGE OU DE VISIBILITE.

DANGER (FRENCH) EVITER LA MORT

• EVITER CETTER ZONE LORSQUE LES BRAS DE LEVAGE RELEVÉS NE SONT PAS ASSURÉS PAR DES ARRETS DE BRAS DE LEVAGE. • UNE PEDALE ACTIONNÉE OU UNE PICE DEFECTUEUSE. PEUT PROVOQUER L’ABAISSEMENT DES BRAS DE LEVAGE.

PELIGRO (SPANISH) EVITE LA MUERTE

• EL FORZAR EL IMPLEMENTO CONTRA EL SUELO

HACE QUE LA RUEDDAS DELANTERAS SE ELEVEN.

• NUNCA SE META DEBAJO NI ALCANCE NADA DEBA-

JO DE LOS BRAZOS DE ELEVACION O DEL CILINDRO DE ELEVACION SIN QUE ESTE INSLADO UN TOPE APROBADO EN LOS BRAZOS DE ELEVACION.

DANGER (FRENCH) EVITER LA MORT

• L’ACCESSOIRE PEUT ETRE APPUYE CONTRE LE SOL ET SOULEVER LES ROUES AVANT.

• NE JAMAIS ALLER SOUS NI METTRE LES MAINS

SOUS LES BRAS OU LE VERIN DE LEVAGE SANS QU’UN ARRET DE BRAS DE LEVAGE APPROUVE SOIT INSTALLE.

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641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

SPECIFICATIONS 641, 642, 643 LOADER SPECIFICATIONS CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 LOADER DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 MACHINE WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 OPERATION & PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 642B LOADER SPECIFICATIONS CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 LOADER DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 OPERATION & PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

SPECIFICATIONS

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641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

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641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

641, 642, 643 LOADER SPECIFICATIONS LOADER DIMENSIONS

• Dimensions are given for loader equipped with standard tires and dirt bucket and may

vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

• Where applicable, specifications conform to SAE standards. Specifications are subject to change without notice.

PI–2206A

This loader was designed without counterweights or ballasts. Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts.

OPERATION & PERFORMANCE 641 642 643 Weights Operating Weight . . . . . . . . . . . . . . . . . . .

4140 lbs. (1878 kg)

Rated Operating Capacity (Melroe) . . . .

Tipping Load (SAE) . . . . . . . . . . . . . . . . . .

1000 lbs. (454 kg) 2000 lbs. (907 kg)

Travel Speed

0.0 to 6.6 MPH (10,6 km/hr.)

Controls Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Function . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direction & speed controlled by two hand operated levers.

Lift, tilt functions controlled by two hand operated levers.

Front auxiliary function controlled by the right steering lever.

Rear auxiliary function controlled by the left steering lever.

Hand lever throttle & shutdown; key type starter switch

Main Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Brakes (Parking) . . . . . . . . . . . . . . . . . . . .

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horsepower . . . . . . . . . . . . . . . . . . . . . . . .

Number of Cylinders . . . . . . . . . . . . . . . . .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . .

Displacement . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Ventilation . . . . . . . . . . . . . . . .

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand lever throttle; pull cable shutdown; key type starter switch

Hydrostatic Mechanical disc, foot operated pedal.

Deutz F2L511 Diesel 27.6 HP (20,6 kW)

Maximum Governed RPM . . . . . . . . . . . .

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand lever throttle; pull cable choke; key type starter switch

Ford I4–98 Gas 32 HP (23,9 kW)

Kubota V1402–BA Diesel 28.5 HP (21,3 kW)

2500 RPM 64.9 ft.–lbs. (88 Nm) @ 2000 RPM Two 3.937 (100)/ 4.14 (105,2) 101 cu. in.

(1655 cm3) Air

72.8 ft.–lbs. (98,7 Nm) @ 1600 RPM Four 3.19 (81)/ 3.06 (77,6) 98 cu. in.

(1606 cm3) Liquid

63.3 ft.–lbs. (85,8 Nm) @ 1600 RPM Three 3.35 (85)/ 3.23 (82) 85.1 cu. in (1395 cm3) Liquid

Pressure System W/Filter Open Dry replaceable paper cartridge (With safety element – Diesel Only) Compression–Diesel

–83–

12 volt, battery ignition W/breaker points and coil.

Compression–Diesel

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

641, 642, 643 LOADER SPECIFICATIONS (Cont’d) HYDRAULIC SYSTEM Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Capacity . . . . . . . . . . . . . . . . . . . . .

System Relief Pressure . . . . . . . . . . . . . .

Hydraulic Fluid Filters . . . . . . . . . . . . . . . .

641

642

Engine driven, gear type 9.5 GPM (36 L/min.) @ 2500 RPM 1900 PSI (13100 kPa) Replaceable cartridge #3 micron paper element in the charge line

Hydraulic Cylinders . . . . . . . . . . . . . . . . .

Bore Diameter Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . .

Rod Diameter Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . .

Stroke Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder(1) . . . . . . . . . . . . . . . . . . . . .

Control Valve . . . . . . . . . . . . . . . . . . . . . . .

Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . .

Doubleacting 2.00 (50,8) 3.25 (82,6) 1.25 (31,8) 1.50 (38,1) 25.00 (635) 14.3 (368) 3–spool, open center series type W/float detent on lift, detent on aux.

SAE standard full flow tubes, hoses & fittings

Hydraulic Function Time Move Lift Arms to Maximum Height . . . .

Lower Lift Arms to Maximum Height . . .

Move Bucket to Dumping Position . . . . .

Move Bucket to Retracted Position . . . .

Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .

643

3.8 seconds 3.2 seconds 3.8 seconds 2.4 seconds Bobcat Fluid (P/N 6563328). If fluid is not available, use 10W–30/10W–40 Class SE Motor Oil for temp. above 0°F (–18°C) & 5W–30 for temp. below 0°F (–18°C)

55 Amps. (Melroe) 37 Amps. (Delco)

55 Amps. (Melroe) 37 Amps. (Delco)

55 Amps. (Melroe) 37 Amps. (Delco)

Belt driven, open

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 volt, 625 cold crank amps. @ 0°F (–17,8°C) 170 Min. Reserve Capacity

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE SYSTEM Transmission . . . . . . . . . . . . . . . . . . . . . . .

Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Total Engine to Wheel Reduction . . . . . . .

12 volt, 435 cold crank amps. @ 0°F (–17,8°C) 125 Min. Reserve Capacity 12 volt, gear drive

12 volt, 625 cold crank amps. @ 0°F (–17,8°C) 170 Min. Reserve Capacity

Tandem hydro. pumps driving 2 fully reversing hydro. motors Gear reduction & #60 HS roller chain & sprockets in sealed chaincase with oil lubrication 29:1

CAPACITIES Cooling System . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication W/Filter . . . . . . . . . . .

Hydraulic/Hydrostatic System . . . . . . . . .

Chaincase Reservoir . . . . . . . . . . . . . . . .

11 qts. (10,4 L) 11 qts (10,4 L) 13 gals. (49 L) 4 qts. (3,8 L) 4 qts. (3,8 L) 7 qts. (6,6 L) 6 gals. (22,7 L) (Includes 3.5 gals (13,2 L) reservoir) 34 qts. (18,9 L)

TIRES Standard . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .

Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .

7:00 – 15, 6–Ply Rating, Nylon W/Bar Lug Tread 45–50 PSI (310–345 kPa) 10 X 16.5, 6 Ply Rating 45–50 PSI (310–345 kPa)

MACHINE WEIGHT (without attachment) Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cooled

4240 lbs. (1923 kg)

–84–

4160 lbs. (1887 kg)

4300 lbs. (1964 kg)

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

642B LOADER SPECIFICATIONS LOADER DIMENSIONS

• Dimensions are given for loader equipped with standard tires and dirt bucket and may

vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

• Where applicable, specifications conform to SAE standards. Specifications are subject to change without notice.

PI–2206

This loader was designed without counterweights or ballasts. Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts.

OPERATION & PERFORMANCE

642B

Weights Operating Weight . . . . . . . . . . . . . . . . . . .

Rated Operating Capacity (Melroe) . . . .

Tipping Load (SAE) . . . . . . . . . . . . . . . . . .

4085 lbs. (1855 kg) 1000 lbs. (454 kg) 2000 lbs. (907 kg)

Travel Speed

Infinitely variable 0 – 6.6 MPH (10,6 km/hr.)

Controls Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Function . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake . . . . . . . . . . . . . . . . . . . . . .

Direction & speed controlled by two hand levers.

Lift & Tilt Functions: Controlled by separate foot pedals.

Hand lever throttle & key type starter switch.

Hydrostatic Mechanical disc, foot operated pedal.

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horsepower . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Governed RPM . . . . . . . . . . . .

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of Cylinders . . . . . . . . . . . . . . . . .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . .

Displacement . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Ventilation . . . . . . . . . . . . . . . .

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mitsubishi 4G32 Gasoline, leaded or unleaded 32 HP (23,9 Kw) 2500 RPM 73 ft.–lbs. (99 Nm) Maximum @ 2000 RPM Four 3.028/3.338 (76,911/84,785) 95.62 cu. in. (1567 cm3) Liquid Full Pressure with full flow filter PCV Dry replacement paper cartridge 12 volt, battery ignition W/breaker points & coil 2600 – 2675 RPM 700 – 800 RPM

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641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

642B LOADER SPECIFICATIONS (Cont’d)

642B

HYDRAULIC SYSTEM Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Capacity . . . . . . . . . . . . . . . . . . . . .

System Relief Pressure . . . . . . . . . . . . . .

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine driven, vane type 10.8 GPM (40,8 L/min.) @ 2600 RPM 1800–1950 PSI (12411–13445 kPa) @ auxiliary couplers Replaceable cartridge #3 micron paper element

Hydraulic Cylinders . . . . . . . . . . . . . . . . .

Bore Diameter Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . .

Rod Diameter Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . .

Stroke Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder(1) . . . . . . . . . . . . . . . . . . . . .

25.00 (635) 12.30 (312,4)

Control Valve . . . . . . . . . . . . . . . . . . . . . . .

Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . .

3–spool open center type W/float on lift, detent on auxiliary (optional) SAE standard tubes, hoses & fittings

Hydraulic Function Time Move Lift Arms to Maximum Height . . . .

Lower Lift Arms to Maximum Height . . .

Move Bucket to Dumping Position . . . . .

Move Bucket to Retracted Position . . . .

3.8 seconds 3.2 seconds 3.0 seconds 2.4 seconds

Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Doubleacting 2.00 (50,8) 3.25 (82,6) 1.25 (31,8) 1.50 (38,1)

Melroe Bobcat Fluid (P/N 6563328) – (5 Gal. Package) If fluid is not available use 10W–30 or 10W–40 Class SE Motor Oil for temperatures above 0°F (–18°C) & 5W–30 Motor Oil for temperatures below 0°F (–18°C)

Belt driven, 55 amps, open 12 volt, 425 cold crank amps. @ 0°F (–17,8°C) 75 min. reserve capacity 12 volt, gear drive

DRIVE SYSTEM Transmission . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic infinitely variable, fully reversing. #60 roller chain in sealed chaincase with oil lubrication

CAPACITIES Cooling System . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lubrication W/Filter . . . . . . . . . . .

Hydraulic/Hydrostatic System . . . . . . . . .

Chaincase Reservoir . . . . . . . . . . . . . . . .

11 qts. (10 L) 13 gals. (49 L) 4.2 qts. (4 L) 6 gals. (23 L) (Includes 3.25 gals. (12,3 L) in reservoir) 34 qts. (18,9 L)

TIRES Standard . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .

Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .

7:00 – 15, 6–Ply Rating, Nylon W/Bar Lug Tread 45–50 PSI (310–345 kPa) 10 X 16.5, 6 Ply Rating 45–50 PSI (310–345 kPa)

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641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

641,642,642B,643Operation&MaintenanceManual#6570241–S[ecoficationsSection

ADDITIONAL PUBLICATIONS The following publications are also available for your Bobcat Loader. You can order them from your Bobcat dealer.

SKID STEER LOADER OPERATOR TRAINING COURSE 6722720

OPERATION & MAINTENANCE MANUAL 6570241

–Introduces operator to step–by–step basics of Skid–Steer loader operation. Also available in Spanish P/N 6724036.

OPERATOR’S HANDBOOK 6569119

SAFETY MANUAL 6556500

–complete instruction on the correct operation and the routine maintenance of the BOBCAT loader.

–provides basic safety procedures and warnings for your BOBCAT loader. Also available is Spanish P/N 6724451.

SERVICE MANUAL 6556619 & 6570275

–gives basic operation instruction and safety warnings.

SAFETY VIDEO 6724793 –gives complete maintenance and overhaul instructions for your BOBCAT loader.

–provides basic safety instructions.

–87–

PARTS MICROFICHE –Up–to–date PARTS information is also available. See your BOBCAT dealer.

641, 642, 642B, 643 Bobcat Loader Operation & Maintenance Manual

–4

540, 543 Loader Service Manual

WARRANTY 400–900 Series Bobcat Loaders The Melroe Company warrants to its authorized dealer and authorized dealers of Melroe Equipment, Ltd., who in turn warrants to the original buyer (owner) that each new Bobcat Loader will be free from proven defects in material and workmanship for 12 months after delivery to the owner.

During the warranty period, the authorized selling Melroe dealer shall repair or replace, at his option, without charge for parts and labor, any part of the Melroe product which fails because of defects in material and workmanship. The owner shall provide the authorized dealer with prompt written notice of the defect and allow reasonable time for replacement or repair. Melroe may, at its option, request failed parts to be returned to the factory. Travel time of mechanics and transportation of the Melroe product to the authorized Bobcat Loader dealer for warranty work are the responsibility of the owner.

The warranty does not apply to tires or other trade accessories not manufactured

by Melroe. The owner shall rely solely on the existing warranty, if any, of the respective manufacturers thereof. Warranty does not cover replacement of scheduled service items such as oil, filters, tune–up parts, and other high–wear items. The warranty does not cover damages resulting from abuse, accidents, alterations, air flow obstructions, or failure to maintain or use the Melroe product according to the instructions applicable to it.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES (EXCEPT THOSE OF TITLE), EXPRESSED OR IMPLIED, AND THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL THE AUTHORIZED SELLING DEALER OR MELROE BE LIABLE FOR DOWNTIME EXPENSES, LOSS OF MACHINE USE OR OTHER INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES.

6570162 (1–96)

Printed in U.S.A.

753 Bobcat Loader Operation & Maintenance Manual