Bobcat 542B Skid-Steer Loader Repair Service Manual - 6570791

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This workshop repair service manual PDF download for the 542B 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 542B 


TABLE OF CONTENTS :

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


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6570791 (5-88)
Total Pages : 214


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
    SERIAL NUMBER LOCATIONS
        Loader Serial Number
        Engine Serial Number
    DELIVERY REPORT
    BOBCAT LOADER IDENTIFICATION
    
PREVENTIVE MAINTENANCE
    SERVICE SCHEDULE
    PREVENTIVE MAINTENANCE
    LIFTING AND BLOCKING THE LOADER
        Procedure
    LIFT ARM STOP
        Procedure
    TRANSPORTING THE BOBCAT LOADER
        Procedure
    OPERATOR CAB
        Operator Cab Fasteners
        Raising And Lowering The Operator Cab
    SEAT BAR SYSTEM
        Seat Bar Description
        Seat Bar Inspection
        Seat Bar Maintenance
    USING AN EXTRA BATTERY (JUMP STARTING)
        Procedure
    AIR CLEANER
        Replacement Of Filter Element
    FUEL SYSTEM
        Filling The Fuel Tank
        Fuel Filter
    ENGINE LUBRICATION SYSTEM
        Checking Engine Oil
        Replacement Of Engine Oil And Filter
    COOLING SYSTEM
        Rear Grill
        Coolant Level
        Removing Coolant From The Cooling System
    HYDRAULIC / HYDROSTATIC SYSTEM
        Checking And Adding Fluid
        Replacement Of The Hydraulic Filter Element
        Removing The Hydraulic Fluid
    FINAL DRIVE TRANSMISSION (CHAINCASE)
        Checking Oil Level
    TIRE MAINTENANCE
        Wheel Nuts
        Tire Rotation
        Tire Inflation
    LUBRICATION OF THE LOADER
        Procedure
    REMOTE START SWITCH
        Procedure
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    TROUBLESHOOTING
    HYDRAULIC SYSTEM INFORMATION
        Flare Connections
        Straight Thread O-Ring Fitting
        Tubelines And Hoses
    LIFT CYLINDER
        Checking The Lift Cylinder(s)
        Removal And Installation
    TILT CYLINDER
        Checking The Tilt Cylinder
        Removal And Installation
        Rod End Seal
    HYDRAULIC CONTROL VALVE
        Checking The Main Relief Valve With Auxiliary Couplers (Opt.)
        Checking The Main Relief Valve Without Auxiliary Hydraulics
        Main Relief Valve Removal And Installation
        Adjusting The Main Relief Valve
        Removal And Installation
    HYDRAULIC PUMP
        Checking The Output Of The Hydraulic Pump
        Removal And Installation
    PORT BLOCK
        Removal And Installation
        Charge By-Pass Valve
    FILTER BY-PASS VALVE
        Removal And Installation
    HYDRAULIC FLUID RESERVOIR
        Removal And Installation
    HYDRAULIC CONTROL PEDALS
        Removal And Installation
        Adjustment
    PEDAL LOCK LINKAGE
        Installation
        Adjustment
        
HYDROSTATIC SYSTEM
    TROUBLESHOOTING
    HYDROSTATIC SYSTEM INFORMATION
        High Pressure Relief/Rreplenishing Valve Function
    FRONT PANEL
        Removal And Installation
    STEERING LEVERS
        Removal And Installation
        Repairing The Steering Levers
    STEERING LINKAGE
        Steering Linkage Adjustment
        Removal And Installation
        Repairing The Pintle Lever
    HYDROSTATIC MOTOR
        Removal And Installation
        Start-Up Procedure
    HYDROSTATIC PUMP
        Checking The Charge Pressure
        Checking High Pressure Relief/Replenishing Valves
        Removal And Installation
        High Pressure Hose Routing
        Start-Up Procedure
    TOWING THE LOADER
        Procedure
        
DRIVE SYSTEM
    PARKING BRAKE
        Adjustment
        Removal And Installation
        Block And Pucks
    AXLES, SEALS AND BEARINGS
        Removal
        Installation
    FINAL DRIVE CHAIN
        Removal
        Installation
    CHAINCASE FLUID
        Replacing The Chaincase Fluid
        
MAIN FRAME
    OPERATOR CAB
        Removal And Installation
    OPERATOR CAB GAS CYLINDER
        Removal And Installation
    REAR DOOR
        Door Latch Adjustment
        Removal And Installation
    LIFT ARMS
        Removal And Installation
    BOB-TACH
        Removal And Installation
        Tilt Cylinder Rod End Seal
        Bob-Tach Wedges
    FUEL TANK
        Removal And Installation
        
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    ELECTRICAL SYSTEM INFORMATION
        Description
    TROUBLESHOOTING
    BATTERY
        Checking The Battery
        Removal And Installation
    ALTERNATOR
        Checking The Alternator Output
        Checking The Alternator Regulator
        Removal And Installation
        Disassenbly And Assembly
        Checking Rotor, Stator And Rectifier
    STARTER
        Checking The Starter
        Removal And Installation
        Disassembly And Assembly
        Cleaning And Inspection
        Replacing The Brushes
        
ENGINE SERVICE
    TROUBLESHOOTING
    VALVE CLEARANCE
        Adjustment
    BELT SHIELD
        Removal And Installation
    FUEL LIFT PUMP
        Checking
        Removal And Installation
    CARBURETOR
        Description
        Operation
        Removal And Installation
        Disassembly And Assembly
        Inspection
    IGNITION SYSTEM
        Description
        Troubleshooting
        Ignition Timing Procedure
    DISTRIBUTOR
        Removal And Installation
        Disassembly And Assembly
        Checking The Distibutor
        Spark Advance Test
    IGNITION - DISTRIBUTORLESS
        Description
        Engine, Speed, Load & Temperature
        Service Adjustments And Checks
        Coil Removal And Installation
        Engine Speed Sensor
        Engine Coolant Temperature Sensor
    GOVENOR
        Belt Adjustment
        Govenor Oil Level
        Removal And Installation
        Adjusting The Govenor
    ENGINE MUFFLER
        Removal And Installation
    RADIATOR
        Removal And Installation
    ENGINE
        Removal And Installation
    OIL COOLER AND BLOWER HOUSING
        Removal And Installation
    FLYWHEEL AND U-JOINT
        Removal And Installation
        Flywheel Ring Gear
    ROCKER ARMS
        Removal And Installation
        Disassembly And Assembly
        Inspection
    CYLINDER HEAD
        Removal And Installation
        Cleaning
        Inspection
    VALVES, VALVE GUIDES & SPRINGS
        Removal
        Valve Guides
        Reconditioning The Valve And Valve Seat
        Valve Springs
    PISTON AND CONNECTING ROD
        Removal And Installation
        Fitting Pistons
        Piston Rings
        Piston Pin
        Connecting Rods
    CYLINDER BLOCK
        Cleaning
        Inspection
        Refinishing Cylinder Bores
    CRANKSHAFT FRONT OIL SEAL
        Removal
        Installation
    CRANKSHAFT REAR OIL SEAL
        Removal
        Installation
    CRANKSHAFT AND MAIN BEARINGS
        Inspection
        Refinishing Crankshaft Journals
        Fitting Bearing with Plastigage
        Crankshaft End Play
    TIMING CHAIN COVER
        Removal And Installation
    TIMING CHAIN AND SPROCKETS
        Removal
        Inspection
        Installation
    CAMSHAFT
        Checking Camshaft Lobe Lift
        Removal And Installation
        Inspection
        Camshaft Bearing
        Camshaft End Play
    PUCH RODS AND TAPPETS
        Inspecting The Push Rods
        Inspecting The Tappet
    OIL PAN
        Removal
        Cleaning And Inspection
        Installation
    OIL PUMP
        Disassembly
        Inspection
        Assembly
        
TECHNICAL DATA
    LOADER/ENGINE SPECIFICATIONS (S/N 11999 & BELOW)
        SPECIFICATIONS
            OPERATION AND PERFORMANCE
            ENGINE
            ELECTRICAL
            DRIVE SYSTEM
            HYDRAULIC SYSTEM
            CAPACITIES
            TIRES
        ENGINE SPECIFICATIONS (S/N 11999 & BELOW)
            Cylinder Block
            Crankshaft
            Connecting Rod
            Pistons
            Piston Pins
            Piston Rings
            Cylinder Head
            Valves
            Valve Springs
            Tappets
            Rocker Arms & Shaft
            Oil Pump
            Camshaft
            Ignition System - Solid State
            Distributor Advance
            Belt Tension
            Fuel Pump
            Engine Torque
        LOADER TORQUES
        HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
        DECIMAL AND MILLIMETER EQUIVALENTS
        U.S. TO METRIC CONVERSION
        STANDARD TORQUE SPECIFICATIONS FOR BOLTS
    LOADER/ENGINE SPECIFICATIONS (S/N 12001 & ABOVE)
        SPECIFICATIONS
            OPERATION AND PERFORMANCE
            ENGINE
            HYDRAULIC SYSTEM
            ELECTRICAL
            DRIVE SYSTEM
            CAPACITIES
            TIRES
        ENGINE SPECIFICATIONS
            Cylinder Block
            Crankshaft
            Connecting Rod
            Pistons
            Piston Pins
            Piston Rings
            Cylinder Head
            Valves
            Valve Springs
            Tappets
            Rocker Arms & Shaft
            Oil Pump
            Camshaft
            Ignition System - Distributorless
            Belt Tension
            Fuel Pump
            Engine Torque
            
SERVICE MANUAL REVISIONS
    542B-1
    542B-2
    542B-3
    542B-4
    542B-5
    542B-6
    542B-7
    
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