Bobcat 540, 543 Skid-Steer Loader Repair Service Manual - 6566181

540 (S/N: 501011999 & Below) - 543 (S/N: 501111999 & Below) 
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This workshop repair service manual PDF download for the 540, 543 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Loader 540, 543 
540 (S/N: 501011999 & Below)
543 (S/N: 501111999 & Below)


TABLE OF CONTENTS :

PREVENTIVE MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
ENGINE SERVICE 
TECHNICAL DATA
ALPHABETICAL INDEX
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6566181 (11–81)
Total Pages : 254


This Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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MAINTENANCE SAFETY
CONTENTS
    FOREWORD
    SAFETY INSTRUCTIONS
    
PREVENTIVE MAINTENANCE
    INTRODUCTION
        Serial Number Identification
        Loader Serial Number
        Engine Serial Number
        Pre–Delivery Inspection
        Thirty Hour Inspection
    SERVICE SCHEDULE
    ENGINE SERVICE (General)
        Air Cleaner Service
        Fuel System
        Engine Lubrication System
        Replacement Of The Engine Oil And Filter
        Engine Cooling System
    ELECTRICAL SYSTEM
        Electrical System Service
        Using An Extra Battery (Booster Starting)
        Installing New Battery
    HYDRAULIC/HYDROSTATIC FLUID
        Replacing The Hydraulic/Hydrostatic Filter
        Checking And Adding Hydraulic/Hydrostatic Fluid
        Removing The Hydraulic/Hydrostatic Fluid
    FINAL DRIVE TRANSMISSION (Chaincase)
        Checking Chaincase Fluid
    SPARK ARRESTOR MUFFLER
        Cleaning The Spark Arrestor Muffler
    OPERATOR GUARD
    LUBRICATION OF THE LOADER
    TRANSPORTING THE BOBCAT LOADER
        Loading The Bobcat Loader
        Fastening The Loader To TheTransport Vehicle
    LIFT ARM STOP
    STOPPING THE BOBCAT LOADER
    
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    TROUBLESHOOTING
    HYDRAULIC SYSTEM INFORMATION
        37° Flare Connections
        Straight Thread O–Ring Fitting
        Tubelines and Hoses
    HYDRAULIC CONTROL VALVE
        Relief Valve
        Checking The Relief Valve
        Removal Of The Relief Valve
        Installation Of The Relief Valve
        Removal Of The Hydraulic Control Valve
        Disassembly Of The Hydraulic Control Valve
        Detent Mechanism
        Assembling the Hydraulic Control Valve
        Installing the Hydraulic Control Valve
    HYDRAULIC PUMP
        Checking Output Of The Hydraulic Pump
        Removal Of The Hydraulic Pump
        Disassembly Of The Hydraulic Pump
        Inspection Of The Hydraulic Pump
        Assembling The Hydraulic Pump
        Installing The Hydraulic Pump
        Start–Up Procedure For The Hydraulic Pump
    LIFT CYLINDERS
        Checking The Lift Cylinders
        Removing The Lift Cylinder
        Disassembly Of The Hydraulic Cylinder
        Assembly Of The Hydraulic Cylinder
        Installation Of The Lift Cylinder
    TILT CYLINDER
        Checking The Tilt Cylinder
        Removing The Tilt Cylinder
        Installation Of The Tilt Cylinder
    HYDRAULIC/HYDROSTATIC RESERVOIR
        Removing The Hydraulic/Hydrostatic Reservoir
        Installation Of The Hydraulic/Hydrostatic Reservoir
    OIL COOLER
        Removing The Oil Cooler (540)
        Installation Of The Oil Cooler (540)
        Removing The Oil Cooler (543)
        Installing The Oil Cooler (543)
    10 MICRON FILTER BY–PASSVALVE
        Removing The By–Pass Valve
        Installation Of The By–Pass Valve
        CONTROL PEDAL, LINKAGE AND LOCKS
        Removing The Control Pedal
        Adjusting The Control Pedal
        Pedal Lock Linkage
        
HYDROSTATIC SYSTEM
    TROUBLESHOOTING
    HYDROSTATIC SYSTEM INFORMATION
        High Pressure Relief Replenishing Valves Function
    STEERING LEVERS
        Removing Steering Levers
        Repairing The Steering Levers
        Installing The Steering Levers
    STEERING LINKAGE
        Adjustment Of The Steering Linkage
        Removing The Steering Linkage
        Repairing The Pintle Lever
        Installing The Steering Linkage
    PORT BLOCK
        Removing The Port Block
        Installing The Port Block
        By–Pass Valve
    HYDROSTATIC MOTOR
        Removing The Hydrostatic Motor
        Disassembly Of The Hydrostatic Motor
        Inspection Of The Hydrostatic Motor
        Assembling The Hydrostatic Motor
        Installing The Hydrostatic Motor
        Start–Up Procedure For The Hydrostatic Motor
    HYDROSTATIC PUMP
        Checking The High Pressure Relief Replenishing Valves
        Checking The Charge Pressure
        Cold Weather By–Pass Valve
        Removing The Hydrostatic Pumps
        Disassembly Of The Hydrostatic Pumps
        Inspection Of The Hydrostatic Pumps
        Assembling The Hydrostatic Pumps
        Installing the Hydrostatic Pumps
        Hydrostatic Pump Start–Up Procedure
        
DRIVE SYSTEM
    BRAKES
        Parking Brake Adjustment
        Parking Brake Removal
        Parking Brake Inspection
        Parking Brake Installation
    FINAL DRIVE CHAINS
        Remove The Drive Chain(s)
        Installing The Drive Chain(s)
    AXLES AND BEARINGS
        Removing Axle(s) and Bearings
        Assembly Of The Axle
        Axle And Bearing Installation
    CHAINCASE FLUID
        Replacing Chaincase Fluid
        
MAIN FRAME
    OPERATOR GUARD
        Raising The Operator Guard
        Lowering The Operator Guard
        Jumper Start Switch
        Removing The Operator Guard
        Installing The Operator Guard
    LIFT ARMS
        Removing The Lift Arms
        Installing The Lift Arms
    BOB–TACH
        Removing The Bob–Tach
        Disassembly Of The Bob–Tach
        Assembly Of The Bob–Tach
        Installing The Bob–Tach
    REAR DOOR
        Removing The Rear Door (Early Model)
        Removing The Rear Door (Later Models)
        Installing The Rear Door
        Adjusting The Rear Door Latch
    FUEL TANK
        Removing The Fuel Tank
        Installing The Fuel Tank
        
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    TROUBLESHOOTING
    ELECTRICAL SYSTEM INFORMATION
        Electrical Circuitry
        Safety Procedures For The Batteries
        Precautions For The Alternator
    BATTERY
        Removing The Battery
        Installing The Battery
    WIRE HARNESS FOR THE OPERATOR GUARD
        Removing The Wire Harness For The Operator Guard
        Installing The Wire Harness For The Operator Guard
    WIRE HARNESS FOR THE ENGINE
    ALTERNATOR SYSTEM (540)
        Checking the A.C. Voltage
        Replacement Of The Stator
    ALTERNATOR SYSTEM (543)
        Belt Adjustment For The Alternator
        Checking The Alternator
        Removing The Alternator
        Repairing The Alternator
        Installing The Alternator
    STARTER (540)
        Checking The Starter
        Removing The Starter
        Repairing The Starter
    STARTER (543)
        Checking The Starter
        Removing The Starter
        Repairing The Starter
        Installing The Starter
        
ENGINE SERVICE
    540 KOHLER ENGINE SERVICE
        TROUBLESHOOTING
        CHECKS & ADJUSTMENTS
            Oil Pressure
            Valve Clearance
            Compression
            Throttle And Governor Linkage
            Ignition System
            Spark Plugs
        CARBURETOR & FUEL SHUT–OFF SOLENOID
            Removing The Carburetor
            Disassembly And Inspection Of The Carburetor
            Assembly Of The Carburetor
            Fuel Shut–off Solenoid
        GOVERNOR
            Removing The Governor
            Installing The Governor
        ENGINE AND HEAT SHIELD
            Removing The Engine
            Installation Of The Engine
            Removing The Heat Shield
            Installing The Heat Shield
        RECONDITIONING THE VALVES
            Repair Of The Valves And Guides
        TIMING COVER, TIMING GEARS AND CAMSHAFT
            Timing Cover
            Timing Gears
            Camshaft And Tappets
        OIL PUMP AND RELIEF VALVE
            Relief Valve
            Oil Pump
            Adjusting Gear Clearance For The Oil Pump
        PISTONS, RODS AND CRANKSHAFT
            Removing Pistons, Rods And Crankshaft
            Crankshaft Bearing And End Play
        CYLINDER HEAD
        INTAKE AND EXHAUST MANIFOLD
        FLYWHEEL
    543 ISUZU ENGINE SERVICE
        TROUBLESHOOTING
        FUEL SYSTEM
            Fuel Filter
            Removing The Air From The Fuel System
            Fuel Lift Pump
            Removal Of The Fuel Injection Pump
            Fuel Injection Pump Drive Gear
            Installation And Timing Of The Fuel Injection Pump
            Fuel Injection Pump Reservoir
            Fuel Injector Nozzles
            Removing The Fuel Injector Nozzles
            Checking The Fuel Injector Nozzles
            Disassembly Of The Fuel Injector Nozzle
            Inspection Of The Fuel Injector Nozzle
            Assembling The Fuel Injectors Nozzle
            nstallation Of The Fuel Injector Nozzles
        ENGINE, BLOWER HOUSING AND RADIATOR
            Removing The Engine
            Installing The Engine
            Installing The Blower Housing
            Removing The Radiator
            Installation Of The Radiator
        ENGINE OVERHAUL
            Disassembly Of The Engine
        ROCKER ARMS AND SHAFT
            Disassembly Of The Rocker Arms
            Inspection Of The Rocker Arms
        CYLINDER HEAD
            Disassembly Of The Cylinder Head
            Inspection Of The Cylinder Head
            Inspection Of The Combustion Chambers
            Inspection And Correction Of The Valves & Guides
            Inspection Of The Valve Springs
            Inspection Of The Push Rods And Tappets
            Installation Of The Hot Plugs
            Assembly Of The Valve System
        CYLINDER BLOCK
            Inspection Of The Cylinder Block
            Correction Of The Cylinder Bores
        PISTONS AND PISTON RINGS
            Disassembly Of The Piston And Rings
            Inspection Of The Pistons
            Inspection Of The Connecting Rods & Bearings
            Assembly Of The Piston & Connecting Rod
            Inspection Of The Connecting Rod Bearings
        CRANKSHAFT
            Inspection Of The Crankshaft And Bearings
        CAMSHAFT
            Inspection Of The Camshaft
        TIMING GEAR
            Inspection Of The Timing Gear
        MANIFOLD ASSEMBLY
            Inspection Of The Manifold Assembly
        OIL PUMP AND OIL FILTER ASSEMBLY
            Disassembly Of The Oil Pump
            Inspection Of The Oil Pump
            Oil Filter Assembly 
            Inspection Of The Oil Filter Assembly
         WATER PUMP 
            Disassembly Of The Water Pump
            Inspection Of The Water Pump
            Assembly Of The Water Pump
        ASSEMBLY OF THE ENGINE
        ENGINE FLYWHEEL
            Removing The Flywheel
            Installing The Flywheel
            
TECHNICAL DATA
    540 LOADER SPECIFICATIONS
        Specifications
        Engine
        Loader Hydraulics
        Electrica
        Drive System
        Capacities
        Tires
    543 LOADER SPECIFICATIONS
        Specifications
        Engine
        Loader Hydraulics
        Electrical
        Drive System
        Capacities
        Tires
    ENGINE SPECIFICATIONS 
        540 LOADER (KOHLER)
            Engine (General)
            Cylinder Bore
            Crankshaft
            Camshaft
            Connecting Rod
            Piston, Pin & Rings
            Valves, Guides & Tappets
            Engine Torque
        543 LOADER (ISUZU)
            Cylinder Block
            Cylinder Head
            Piston
            Piston Ring
            Connecting Rod
            Crankshaft
            Camshaft
            Timing Gear
            Valve
            Valve Spring
            Tappet
            Oil Pump and Relief Valve
            Water Pump
            Fuel Lift Pump
            Fuel Injector
            Engine Torque
        TORQUE SPECIFICATIONS
            Engine Group – 540 Loader
            Engine Group – 543 Loader
            Engine Group – 543 Loader
            Seat Bar, Fuel Tank & Panel Group
            Steering Levers, Linkage & Pedal Group
            Mainframe Group
            Hydrostatic Group – 540 Loader
            Hydrostatic Group – 543 Loader
            Hydraulic Group
        HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
            Hydraulic/Hydrostatic Fluid
        DECIMAL AND MILLIMETER EQUIVALENTS
        U.S. TO METRIC CONVERSION
        STANDARD TORQUE SPECIFICATIONS FOR BOLTS
        
ALPHABETICAL INDEX

SERVICE MANUAL REVISIONS
    540–1
    540–2
    540–2
    540–3
    540–4
    540–5
    540–6
    
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