Bobcat 540, 543 Skid-Steer Loader Repair Service Manual - 6566532

540 (S/N: 501012001 & Above) - 543 (S/N: 502412001 & Above) - 543B (S/N: 511111001 & Above) 
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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: 501012001 & Above)
543 (S/N: 502412001 & Above)
543B (S/N: 511111001 & Above)


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 : 6566532 (11–94)
Total Pages : 322


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

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
    FOREWORD
    SAFETY INSTRUCTIONS
    
PREVENTIVE MAINTENANCE
    INTRODUCTION
        Serial Number Identification
        Loader Serial Number
        Engine Serial Number
         Delivery Report
    SERVICE SCHEDULE
    ENGINE SERVICE (General)
        Air Cleaner Service (540)
        Air Cleaner Service (543)
        Fuel System
        Replacement of the Engine Oil and Filter
        Engine Cooling System (540)
        Engine Cooling System (543)
    ELECTRICAL SYSTEM
        Electrical System Service
        Using an Extra Battery (Booster Starting)
         Installing New Battery
    SPARK ARRESTOR MUFFLER
    HYDRAULIC/HYDROSTATIC SYSTEM
        Replacing The Hydraulic Filter Element
        Checking & Adding Hydraulic/HydrostaticFluid
        Removing The Hydraulic/Hydrostatic Fluid
    FINAL DRIVE TRANSMISSION (CHAINCASE)
        Checking/Adding Chaincase Fluid
    TIRE MAINTENANCE
        Tire Rotation
        Wheel Nuts
    LUBRICATION OF THE LOADER
        Lubrication Of The Loader
    ROLL OVER PROTECTION STRUCTURE (ROPS & FOPS)
        Operator Cab
    TRANSPORTING THE BOBCAT LOADER
        Loading The Bobcat Loader
        Fastening The Loader To The Transport Vehicle
        Lifting The Loader
        Towing The Loader
    LIFT ARM SUPPORT DEVICE
        Installing the Approved Lift Arm Support Device
    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
        Check 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 CONTROL VALVE (MELROE)
        Relief Valve
        Check The Relief Valve
        Adjusting The Relief Valve
        Relief Valve Service
        Installation Of A New Relief Valve
        Removal Of The Hydraulic Control Valve (Melroe)
        Disassembly Of The Control Valve
        Inspection Of The Control Valve
        Assembly Of The Control Valve
        Installation Of The Control Valve
    HYDRAULIC PUMP
        Checking Output Of Hydraulic Pump
        Removal Of The Hydraulic Pump
        Disassembly Of The Hydraulic Pump
        Inspection Of The Hydraulic Pump
        Assembling The Hydraulic Pump
        Installation To 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)
        Installation Of The Oil Cooler (543)
    10 MICRON FILTER BY–PASS VALVE
        Remove The By–Pass Valve
        Installation Of The By–Pass Valve
    CONTROL PEDAL, LINKAGE AND LOCKS
        Removing The Control Pedal
        Installation Of 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
        Charge By–Pass Valve
    HYDROSTATIC MOTOR
        Removing The Hydrostatic Motor
            Motors With Keyed–Shaft
            Motors With Splined–Shaft
        Disassembly of the Hydrostatic Motor
        Hydrostatic Motor Inspection
        Assembly Of The Hydrostatic Motor
        Installing The Hydrostatic Motor
            Keyed–Shaft Motors
            Splined–Shaft Motors
        Start–Up Procedure For The Hydrostatic Motor
    HYDROSTATIC PUMP
        Checking The High Pressure Relief Replenishing Valves
        Checking The Charge Pressure
        Removing The Hydrostatic Pump
        Disassembly Of The Hydrostatic Pump
        Inspection Of The Hydrostatic Pumps
        Assembling The Hydrostatic Pumps
        Installing The Hydrostatic Pumps
        Start–Up Procedure For The Hydrostatic Pump
    TOWING THE BOBCAT LOADER
        Installation Of The Tool For The High Pressure Relief Valves
        
DRIVE SYSTEM
    PARKING BRAKE
        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 CAB
        Raising The Operator Cab
        Lowering The Operator Cab
        Jumper Start Switch
        Removing The Operator Cab
        Removing The Gas Cylinder
        Installing The Operator Cab
    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
        Installing The Rear Door
        Adjusting The Rear Door Latch
    FUEL TANK
        Removing The Fuel Tank
        Installing The Fuel Tank
    SEAT BAR
        Removal And Installation
    SEAT BAR SYSTEM
        Seat Bar Inspection
        Seat Bar Maintenance
    PEDAL LOCK LINKAGE
        Adjustment
    REAR WINDOW
        Installing Rear Window
        
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 CAB
        Removing The Wire Harness For The Operator Cab
        Installing The Wire Harness For The Operator Cab
    WIRE HARNESS FOR THE ENGINE
     ALTERNATOR SYSTEM (540)
        Checking The Alternator
        Replacing The Stator
    ALTERNATOR SYSTEM (543)
        Adjusting The Alternator Belt
        Alternator Output Test (New Style)
        Rectifier (Diode) Test (New Style)
        Alternator Regulator Test (New Style)
        Checking The Alternator (Early Models)
        Parts Identification (New Style)
        Disassembly And Assembly (New Style)
        Stator Continuity Test
        Stator Ground Test
        Rotor Continuity Test
        Rotor Ground Test
        Rectifier Continuity (Diode) Test
        Removing The Alternator (Early Models)
        Repairing The Alternator (Early Models)
        Installing The Alternator (Early Models)
    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
    ENGINE SERVICE (540) KOHLER
        TROUBLESHOOTING
        CHECKS AND ADJUSTMENTS FOR THE ENGINE
            Engine Oil Pressure
            Valve Clearance
            Compression
            Throttle And Governor Linkage
            Ignition System
            Spark Plugs
        CARBURETOR & FUELSHUT–OFF SOLENOID
            Removing The Carburetor
            Disassembly And Inspection Of The Carburetor 
            Assembly Of The Carburetor
            Fuel Shut–off Solenoid
            Non–Metallic Bodied Fuel Pumps
        GOVERNOR
            Removing The Governor
            Installing The Governor
        ENGINE AND HEAT SHIELD
            Removing The Engine
            Installing The Engine
            Removing The Heat Shield
            Installing The Heat Shield
        RECONDITIONING THEVALVES
            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
    ENGINE SERVICE (543 & 543B) KUBOTA
        TROUBLESHOOTING
        FUEL SYSTEM
            Replacing The Fuel Filter
            To Remove The Air From The Fuel System
            Fuel Injection Pump
            Checking The Injection Pump
            Installation
            Timing The Fuel Injection Pump
            Fuel Injector Nozzles
            Removal
            Checking The Fuel Injector Nozzles
            Installation
            Checking Glow Plugs
        ENGINE AND ATTACHING PARTS
            Removing The Engine
            Installing The Engine
            Engine Muffler
            Engine Radiator Removal
            Engine Radiator Installation
            Engine Blower Housing Removal
            Engine Blower Housing Installation
            Engine Blower Fan And Flywheel Removal
            Engine Blower Fan And Flywheel Installation
        CYLINDER HEAD
            Removing The Cylinder Head
            Disassembly Of The Cylinder Head
            Servicing The Cylinder Head
             Assembly Of The Cylinder Head
            Installing The Cylinder Head
            Adjusting the Compression Release Mechanism
        REPAIRING THE ENGINE
            Removing The Gear Case
            Removing The Timing Gear, Camshaft & Oil Pump
            Removing Pistons And Crankshaft
            Servicing The Timing Gear And The Camshaft
            Servicing The Connecting Rods And Pistons
            Servicing The Crankshaft
            Servicing The Cylinder Liners
            Servicing The Oil Pump
            Servicing The Water Pump
        ASSEMBLY OF THE ENGINE
            Installing The Crankshaft
            Installing The Pistons
            Installing The Camshaft And Timing Gears
            Installing The Gear Case Cover
            
TECHNICAL DATA
    (540) KOHLER LOADER SPECIFICATIONS
        Operation & Performance
        Engine
        Loader Hydraulics
        Electrical
        Drive System
        Capacities
        Tires
    ENGINE SPECIFICATIONS – 540 LOADER (KOHLER)
        Engine (General)
        Cylinder Bore
        Crankshaft
        Camshaft
        Connecting Rod
        Piston, Pin And Rings
        Valves, Guides & Tappets
        Engine Torque
    543 & 543B KUBOTA LOADER SPECIFICATIONS
        Operation & Performance
        Engine
        Loader Hydraulics
        Electrical
        Drive System
        Capacities
        Tires 
    ENGINE SPECIFICATIONS - 543-543B LOADER
        Fuel Injector Nozzles
        Fuel Injection Pump
        Cylinder Head
        Valves
        Valve Springs
        Rocker Arms
        Camshaft
        Cylinders
        Piston Rings
        Piston
        Crankshaft
        Oil Pump
        Thermostat
        Engine Torque
        Grinding Specifications for the Crankshaft
    TORQUE SPECIFICATIONS
        Engine Group – 540 Loader
        Engine Group – 543 Loader
        Fuel System Group
        Steering Levers & Panel Group
        Bob–Tach & Lift Arm Group
        Seat Bar & Pedal Group
        Brake, Chaincase & Axle Group
        Hydraulic Group
        Operator Cab, Main Frame & Rear Door Group
        Hydrostatic Group–540 Loader
        Hydrostatic Group–543 Loader
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
        Hydraulic/Hydrostatic Fluid
    DECIMAL AND MILLIMETER EQUIVALENTS
    U.S. TO METRIC CONVERSION
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS
    
SERVICE MANUAL REVISIONS
    540–3
    540–4
    540–5
    540–6
    540–7
    540–8
    540–9
    540–11
    540–13
    540–14
    540–15
    540–16
    540–17
    540–1 Thru 540–17
    540–18
    540–19
    
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