Complete repair service manual with Electrical Wiring Diagrams for Bobcat Loaders 540, 542B, 543, 543B, with workshop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Bobcat Loaders 540, 542B, 543, 543B workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6556844 (6-82) - 540 Loader Operator's Manual.pdf
6556846 (8-82) - 543 Loader Operator's Manual.pdf
6566181 (6-12) - 540, 543 Loader Service Manual.pdf
6566181 (11-81) - 540, 543 Loader Service Manual.pdf
6566276 (9-96) - 543 Operation & Maintenance Manual.pdf
6566282 (11-82) - 540 Loader Operator's Manual.pdf
6566532 (6-12) - 540, 543, 543B Loader Service Manual.pdf
6566532 (11-94) - 540, 543, 543B Loader Service Manual.pdf
6566655 (5-84) - 540 Loader Operator's Manual.pdf
6566656 (9-83) - 543 Loader Operator's Manual.pdf
6566858 (8-84) - 540 Loader Operator's Manual.pdf
6570791 (5-88) - 542B Loader Service Manual.pdf
6570791 (6-12) - 542B Loader Service Manual.pdf
6720184 (9-96) - 542B, 543 Operation & Maintenance Manual.pdf
6720358 (11-89) - 542B Operation & Maintenance Manual.pdf
6722480 (3-99) - 543B Loader Operation & Maintenance Manual.pdf
6722584 (11-98) - 543 Loader Operation & Maintenance Manual.pdf

Total Pages: 2,322 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
6556844 (6-82) - 540 Loader Operator& Manual...1
  SAFETY INSTRUCTIONS...3
    SAFETY IS YOUR RESPONSIBILITY...3
    BEFORE YOU OPERATE THE BOBCAT LOADER...3
  FOREWORD...5
    CONTENTS...5
    REFERENCE INFORMATION...5
    540 BOBCAT LOADER IDENTIFICATION...6
  OPERATING INSTRUCTIONS...7
    OPERATING INSTRUCTIONS...9
    CONTROLS...11
    DASH PANEL...11
    THROTTLE CONTROL...12
    CHOKE CONTROL...12
    TO STOP THE ENGINE...12
    PARKING BRAKE...12
    STEERING LEVERS...13
    HYDRAULIC CONTROLS...14
    BEFORE YOU START THE ENGINE...15
    STARTING THE ENGINE...16
      Normal Starting Condition...17
      Cold Temperature Starting Condition...17
    BOBCAT LOADER OPERATION...18
      Bucket Size...18
      Installation Of Attachments...19
      Removal Of Attachments...19
    OPERATION OF THE BOBCAT LOADER...20
      Filling The Bucket...21
      To Empty The Bucket...21
      Digging Into The Ground...22
      Making The Ground Level...22
      Filling A Hole...22
    STOPPING THE BOBCAT LOADER...23
    TRANSPORTING THE BOBCAT LOADER...23
    LIFT ARM STOP...24
    LIFT THE OPERATOR GUARD...25
    LOWERING THE OPERATOR GUARD...25
  PREVENTIVE MAINTENANCE...27
    SERVICE SCHEDULE...29
    ENGINE SERVICE...30
    AIR CLEANER SERVICE...30
    FUEL SYSTEM...31
    FUEL SYSTEM SERVICE...31
    FUEL FILTER...31
    ENGINE LUBRICATION SYSTEM...32
    REPLACEMENT OF ENGINE OIL AND FILTER...32
    ENGINE COOLING SYSTEM...33
    ELECTRICAL SYSTEM...33
    USING AN EXTRA BATTERY (JUMP STARTING)...35
    TO INSTALL A NEW BATTERY...36
    SPARK ARRESTOR MUFFLER...37
    HYDRAULIC SYSTEM...37
    HYDRAULIC / HYDROSTATIC OIL RESERVOIR...39
      Checking And Adding Oil...39
      Removing Hydraulic Oil...39
    REPLACEMENT OF THE HYDRAULIC FILTER...40
    FINAL DRIVE TRANSMISSION (CHAINCASE)...40
    TIRE MAINTENANCE...40
      Tire Rotation...41
    LUBRICATION OF THE BOBCAT LOADER...41
    OPERATOR GUARD (ROPS & FOPS)...42
    BOB-TACH...43
    PIVOT PINS...43
    AUXILIARY CONTROL LOCKBOLT...43
    BRAKE PEDAL ADJUSTMENT...43
    DELIVERY REPORT...44
  TROUBLESHOOTING...45
    TROUBLESHOOTING THE ENGINE...47
    TROUBLESHOOTING THE DRIVE SYSTEM...48
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...49
  DECALS...51
    DECALS...53
    SERVICE SCHEDULE - 6561387...54
    WARNING - 6563484...56
    WARNING - 6563380...57
    WARNING - 6561380 ...58
    IMPORTANT - 6560573...59
  GENERAL INFORMATION...61
    LOADER SPECIFICATIONS...63
      Operation & Performance...63
      Engine...63
      Hydraulic System...64
      Hydrostatic Transmission & Final Drive...64
      Electrical...64
      Tires...64
      Fluid Capacities...64
    ADDITIONAL PUBLICATIONS...65
  WARRANTY...67
6556846 (8-82) - 543 Loader Operator& Manual...69
  SAFETY INSTRUCTIONS...71
    SAFETY IS YOUR RESPONSIBILITY...71
    BEFORE YOU OPERATE THE BOBCAT LOADER...71
  FOREWORD...73
    CONTENTS...73
    REFERENCE INFORMATION...73
    543 BOBCAT LOADER IDENTIFICATION...74
  OPERATING INSTRUCTIONS...75
    OPERATING INSTRUCTIONS...77
    CONTROLS...79
    DASH PANEL...79
    THROTTLE CONTROL...80
    TO STOP THE ENGINE...80
    PARKING BRAKE...80
    STEERING LEVERS...81
    HYDRAULIC CONTROLS...82
    BEFORE YOU START THE ENGINE...83
    STARTING THE ENGINE...84
      Normal Starting Condition...85
      Cold Temperature Starting Condition...85
    BOBCAT LOADER OPERATION...86
      Bucket Size...86
      Installation Of Attachments...87
      Removal Of Attachments...87
    OPERATING PROCEDURE...88
      Filling The Bucket...89
      To Empty The The Bucket...89
      Digging Into The Ground...90
      Making The Ground Level By Using Float Position...90
      Filling A Hole...90
    STOPPING THE BOBCAT LOADER...91
    TRANSPORTING THE BOBCAT LOADER...91
    LIFT ARM STOP...92
    LIFTING THE OPERATOR GUARD...93
    LOWERING THE OPERATOR GUARD...93
  PREVENTIVE MAINTENANCE...95
    SERVICE SCHEDULE...99
    ENGINE SERVICE...100
    AIR CLEANER SERVICE...100
    FUEL SYSTEM...101
    FUEL SYSTEM SERVICE...101
    FUEL FILTER...102
    ENGINE LUBRICATION SYSTEM...102
    REPLACEMENT OF ENGINE OIL AND FILTER...102
    FUEL INJECTION PUMP RESERVOIR...104
    ENGINE COOLING SYSTEM...104
    ELECTRICAL SYSTEM...105
    USING AN EXTRA BATTERY (JUMP STARTING)...107
    TO INSTALL A NEW BATTERY...108
    SPARK ARRESTOR MUFFLER...109
    HYDRAULIC SYSTEM ...109
    HYDRAULIC / HYDROSTATIC OIL RESERVOIR...111
      Checking And Adding Oil...111
      Removing Hydraulic Oil...111
    REPLACEMENT OF THE HYDRAULIC FILTER...112
    FINAL DRIVE TRANSMISSION (CHAINCASE)...112
    TIRE MAINTENANCE...112
      Tire Rotation...112
    LUBRICATION OF THE BOBCAT LOADER...113
    OPERATOR GUARD...114
    BOB-TACH...114
    PIVOT PINS...114
    AUXILIARY CONTROL LOCKBOLT...115
    BRAKE PEDAL ADJUSTMENT...115
    DELIVERY REPORT...115
  TROUBLESHOOTING...117
    TROUBLESHOOTING THE ENGINE...119
    TROUBLESHOOTING THE DRIVE SYSTEM...120
    TROUBLESHOOTING HTE ENGINE...121
  DECALS...123
    DECALS...125
    SERVICE SCHEDULE - 6561387...126
    WARNING - 6563484...128
    WARNING - 6563380...129
    WARNING - 6561380 ...130
    IMPORTANT - 6560573...131
  GENERAL INFORMATION...133
    LOADER SPECIFICATIONS...135
      Operational & Performance...135
      Pallet Fork Weight Distribution Specifications...135
      Engine...136
      Loader Hydraulics...136
      Electrical...136
      Drive System...136
      Capacities...136
      Tires...136
    ADDITIONAL PUBLICATIONS...137
  WARRANTY...139
6566181 (11-81) - 540, 543 Loader Service Manual...141
  MAINTENANCE SAFETY...143
  CONTENTS...145
    FOREWORD...145
    SAFETY INSTRUCTIONS...147
  PREVENTIVE MAINTENANCE...149
    INTRODUCTION...151
      Serial Number Identification...151
      Loader Serial Number...151
      Engine Serial Number...151
      Pre–Delivery Inspection...151
      Thirty Hour Inspection...152
    SERVICE SCHEDULE...153
    ENGINE SERVICE (General)...154
      Air Cleaner Service...154
      Fuel System...155
      Engine Lubrication System...156
      Replacement Of The Engine Oil And Filter...156
      Engine Cooling System...157
    ELECTRICAL SYSTEM...158
      Electrical System Service...158
      Using An Extra Battery (Booster Starting)...158
      Installing New Battery...160
    HYDRAULIC/HYDROSTATIC FLUID...161
      Replacing The Hydraulic/Hydrostatic Filter...161
      Checking And Adding Hydraulic/Hydrostatic Fluid...161
      Removing The Hydraulic/Hydrostatic Fluid...162
    FINAL DRIVE TRANSMISSION (Chaincase)...163
      Checking Chaincase Fluid...163
    SPARK ARRESTOR MUFFLER...163
      Cleaning The Spark Arrestor Muffler...163
    OPERATOR GUARD...164
    LUBRICATION OF THE LOADER...164
    TRANSPORTING THE BOBCAT LOADER...165
      Loading The Bobcat Loader...165
      Fastening The Loader To TheTransport Vehicle...165
    LIFT ARM STOP...166
    STOPPING THE BOBCAT LOADER...166
  HYDRAULIC SYSTEM...167
    HYDRAULIC / HYDROSTATIC SCHEMATICS...169
    TROUBLESHOOTING...179
    HYDRAULIC SYSTEM INFORMATION...180
      37° Flare Connections...180
      Straight Thread O–Ring Fitting...180
      Tubelines and Hoses...180
    HYDRAULIC CONTROL VALVE...181
      Relief Valve...181
      Checking The Relief Valve...181
      Removal Of The Relief Valve...182
      Installation Of The Relief Valve...182
      Removal Of The Hydraulic Control Valve...183
      Disassembly Of The Hydraulic Control Valve...184
      Detent Mechanism...185
      Assembling the Hydraulic Control Valve...186
      Installing the Hydraulic Control Valve...188
    HYDRAULIC PUMP...188
      Checking Output Of The Hydraulic Pump...189
      Removal Of The Hydraulic Pump...189
      Disassembly Of The Hydraulic Pump...190
      Inspection Of The Hydraulic Pump...191
      Assembling The Hydraulic Pump...191
      Installing The Hydraulic Pump...193
      Start–Up Procedure For The Hydraulic Pump...193
    LIFT CYLINDERS...193
      Checking The Lift Cylinders...193
      Removing The Lift Cylinder...194
      Disassembly Of The Hydraulic Cylinder...195
      Assembly Of The Hydraulic Cylinder...196
      Installation Of The Lift Cylinder...198
    TILT CYLINDER...199
      Checking The Tilt Cylinder...199
      Removing The Tilt Cylinder...200
      Installation Of The Tilt Cylinder...201
    HYDRAULIC/HYDROSTATIC RESERVOIR...201
      Removing The Hydraulic/Hydrostatic Reservoir...201
      Installation Of The Hydraulic/Hydrostatic Reservoir...202
    OIL COOLER...202
      Removing The Oil Cooler (540)...202
      Installation Of The Oil Cooler (540)...203
      Removing The Oil Cooler (543)...203
      Installing The Oil Cooler (543)...204
    10 MICRON FILTER BY–PASSVALVE...204
      Removing The By–Pass Valve...204
      Installation Of The By–Pass Valve...205
      CONTROL PEDAL, LINKAGE AND LOCKS...205
      Removing The Control Pedal...205
      Adjusting The Control Pedal...206
      Pedal Lock Linkage...206
  HYDROSTATIC SYSTEM...209
    TROUBLESHOOTING...211
    HYDROSTATIC SYSTEM INFORMATION...212
      High Pressure Relief Replenishing Valves Function...212
    STEERING LEVERS...213
      Removing Steering Levers...213
      Repairing The Steering Levers...214
      Installing The Steering Levers...214
    STEERING LINKAGE...215
      Adjustment Of The Steering Linkage...215
      Removing The Steering Linkage...216
      Repairing The Pintle Lever...217
      Installing The Steering Linkage...217
    PORT BLOCK...218
      Removing The Port Block...218
      Installing The Port Block...218
      By–Pass Valve...219
    HYDROSTATIC MOTOR...219
      Removing The Hydrostatic Motor...219
      Disassembly Of The Hydrostatic Motor...221
      Inspection Of The Hydrostatic Motor...223
      Assembling The Hydrostatic Motor...224
      Installing The Hydrostatic Motor...227
      Start–Up Procedure For The Hydrostatic Motor...227
    HYDROSTATIC PUMP...228
      Checking The High Pressure Relief Replenishing Valves...228
      Checking The Charge Pressure...229
      Cold Weather By–Pass Valve...229
      Removing The Hydrostatic Pumps...230
      Disassembly Of The Hydrostatic Pumps...231
      Inspection Of The Hydrostatic Pumps...235
      Assembling The Hydrostatic Pumps...236
      Installing the Hydrostatic Pumps...239
      Hydrostatic Pump Start–Up Procedure...240
  DRIVE SYSTEM...243
    BRAKES...245
      Parking Brake Adjustment...245
      Parking Brake Removal...245
      Parking Brake Inspection...247
      Parking Brake Installation...247
    FINAL DRIVE CHAINS...249
      Remove The Drive Chain(s)...249
      Installing The Drive Chain(s)...250
    AXLES AND BEARINGS...251
      Removing Axle(s) and Bearings...251
      Assembly Of The Axle...252
      Axle And Bearing Installation...253
    CHAINCASE FLUID...254
      Replacing Chaincase Fluid...254
  MAIN FRAME...255
    OPERATOR GUARD...257
      Raising The Operator Guard...257
      Lowering The Operator Guard...257
      Jumper Start Switch...258
      Removing The Operator Guard...258
      Installing The Operator Guard...259
    LIFT ARMS...259
      Removing The Lift Arms...259
      Installing The Lift Arms...260
    BOB–TACH...261
      Removing The Bob–Tach...261
      Disassembly Of The Bob–Tach...262
      Assembly Of The Bob–Tach...263
      Installing The Bob–Tach...264
    REAR DOOR...265
      Removing The Rear Door (Early Model)...265
      Removing The Rear Door (Later Models)...265
      Installing The Rear Door...266
      Adjusting The Rear Door Latch...266
    FUEL TANK...267
      Removing The Fuel Tank...267
      Installing The Fuel Tank...267
  ELECTRICAL SYSTEM...269
    ELECTRICAL SCHEMATICS...272
    TROUBLESHOOTING...279
    ELECTRICAL SYSTEM INFORMATION...280
      Electrical Circuitry...280
      Safety Procedures For The Batteries...280
      Precautions For The Alternator...281
    BATTERY...281
      Removing The Battery...281
      Installing The Battery...282
    WIRE HARNESS FOR THE OPERATOR GUARD...282
      Removing The Wire Harness For The Operator Guard...282
      Installing The Wire Harness For The Operator Guard...283
    WIRE HARNESS FOR THE ENGINE...283
    ALTERNATOR SYSTEM (540)...284
      Checking the A.C. Voltage...284
      Replacement Of The Stator...284
    ALTERNATOR SYSTEM (543)...284
      Belt Adjustment For The Alternator...284
      Checking The Alternator...285
      Removing The Alternator...286
      Repairing The Alternator...287
      Installing The Alternator...288
    STARTER (540)...289
      Checking The Starter...289
      Removing The Starter...289
      Repairing The Starter...289
    STARTER (543)...290
      Checking The Starter...290
      Removing The Starter...290
      Repairing The Starter...291
      Installing The Starter...293
  ENGINE SERVICE...295
    540 KOHLER ENGINE SERVICE...297
      TROUBLESHOOTING...299
      CHECKS & ADJUSTMENTS...301
        Oil Pressure...301
        Valve Clearance...301
        Compression...302
        Throttle And Governor Linkage...302
        Ignition System...303
        Spark Plugs...303
      CARBURETOR & FUEL SHUT–OFF SOLENOID...304
        Removing The Carburetor...304
        Disassembly And Inspection Of The Carburetor...304
        Assembly Of The Carburetor...304
        Fuel Shut–off Solenoid...305
      GOVERNOR...305
        Removing The Governor...305
        Installing The Governor...305
      ENGINE AND HEAT SHIELD...306
        Removing The Engine...306
        Installation Of The Engine...307
        Removing The Heat Shield...307
        Installing The Heat Shield...308
      RECONDITIONING THE VALVES...308
        Repair Of The Valves And Guides...308
      TIMING COVER, TIMING GEARS AND CAMSHAFT...309
        Timing Cover...309
        Timing Gears...309
        Camshaft And Tappets...310
      OIL PUMP AND RELIEF VALVE...310
        Relief Valve...310
        Oil Pump...310
        Adjusting Gear Clearance For The Oil Pump...310
      PISTONS, RODS AND CRANKSHAFT...311
        Removing Pistons, Rods And Crankshaft...311
        Crankshaft Bearing And End Play...312
      CYLINDER HEAD...313
      INTAKE AND EXHAUST MANIFOLD...313
      FLYWHEEL...313
    543 ISUZU ENGINE SERVICE...315
      TROUBLESHOOTING...317
      FUEL SYSTEM...319
        Fuel Filter...319
        Removing The Air From The Fuel System...319
        Fuel Lift Pump...319
        Removal Of The Fuel Injection Pump...320
        Fuel Injection Pump Drive Gear...320
        Installation And Timing Of The Fuel Injection Pump...321
        Fuel Injection Pump Reservoir...321
        Fuel Injector Nozzles...322
        Removing The Fuel Injector Nozzles...322
        Checking The Fuel Injector Nozzles...323
        Disassembly Of The Fuel Injector Nozzle...324
        Inspection Of The Fuel Injector Nozzle...324
        Assembling The Fuel Injectors Nozzle...324
        nstallation Of The Fuel Injector Nozzles...325
      ENGINE, BLOWER HOUSING AND RADIATOR...325
        Removing The Engine...327
        Installing The Engine...328
        Installing The Blower Housing...329
        Removing The Radiator...330
        Installation Of The Radiator...332
      ENGINE OVERHAUL...333
        Disassembly Of The Engine...333
      ROCKER ARMS AND SHAFT...334
        Disassembly Of The Rocker Arms...334
        Inspection Of The Rocker Arms...335
      CYLINDER HEAD...335
        Disassembly Of The Cylinder Head...335
        Inspection Of The Cylinder Head...336
        Inspection Of The Combustion Chambers...336
        Inspection And Correction Of The Valves & Guides...336
        Inspection Of The Valve Springs...338
        Inspection Of The Push Rods And Tappets...338
        Installation Of The Hot Plugs...338
        Assembly Of The Valve System...338
      CYLINDER BLOCK...339
        Inspection Of The Cylinder Block...339
        Correction Of The Cylinder Bores...339
      PISTONS AND PISTON RINGS...339
        Disassembly Of The Piston And Rings...339
        Inspection Of The Pistons...340
        Inspection Of The Connecting Rods & Bearings...340
        Assembly Of The Piston & Connecting Rod...341
        Inspection Of The Connecting Rod Bearings...341
      CRANKSHAFT...342
        Inspection Of The Crankshaft And Bearings...342
      CAMSHAFT...342
        Inspection Of The Camshaft...342
      TIMING GEAR...343
        Inspection Of The Timing Gear...343
      MANIFOLD ASSEMBLY...343
        Inspection Of The Manifold Assembly...343
      OIL PUMP AND OIL FILTER ASSEMBLY...343
        Disassembly Of The Oil Pump...343
        Inspection Of The Oil Pump...344
        Oil Filter Assembly ...344
        Inspection Of The Oil Filter Assembly...344
       WATER PUMP ...344
        Disassembly Of The Water Pump...344
        Inspection Of The Water Pump...345
        Assembly Of The Water Pump...345
      ASSEMBLY OF THE ENGINE...346
      ENGINE FLYWHEEL...349
        Removing The Flywheel...349
        Installing The Flywheel...349
  TECHNICAL DATA...351
    540 LOADER SPECIFICATIONS...353
      Specifications...353
      Engine...353
      Loader Hydraulics...354
      Electrica...354
      Drive System...354
      Capacities...354
      Tires...354
    543 LOADER SPECIFICATIONS...355
      Specifications...355
      Engine...355
      Loader Hydraulics...356
      Electrical...356
      Drive System...356
      Capacities...356
      Tires...356
    ENGINE SPECIFICATIONS ...357
      540 LOADER (KOHLER)...357
        Engine (General)...357
        Cylinder Bore...357
        Crankshaft...357
        Camshaft...357
        Connecting Rod...357
        Piston, Pin & Rings...357
        Valves, Guides & Tappets...357
        Engine Torque...358
      543 LOADER (ISUZU)...359
        Cylinder Block...359
        Cylinder Head...359
        Piston...359
        Piston Ring...359
        Connecting Rod...359
        Crankshaft...359
        Camshaft...359
        Timing Gear...359
        Valve...360
        Valve Spring...360
        Tappet...360
        Oil Pump and Relief Valve...360
        Water Pump...360
        Fuel Lift Pump...360
        Fuel Injector...360
        Engine Torque...361
      TORQUE SPECIFICATIONS...362
        Engine Group – 540 Loader...362
        Engine Group – 543 Loader...363
        Engine Group – 543 Loader...364
        Seat Bar, Fuel Tank & Panel Group...365
        Steering Levers, Linkage & Pedal Group...366
        Mainframe Group...368
        Hydrostatic Group – 540 Loader...369
        Hydrostatic Group – 543 Loader...370
        Hydraulic Group...371
      HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...372
        Hydraulic/Hydrostatic Fluid...372
      DECIMAL AND MILLIMETER EQUIVALENTS...373
      U.S. TO METRIC CONVERSION...373
      STANDARD TORQUE SPECIFICATIONS FOR BOLTS...374
  ALPHABETICAL INDEX...375
  SERVICE MANUAL REVISIONS...381
    540–1...381
    540–2...383
    540–2...385
    540–3...387
    540–4...389
    540–5...391
    540–6...393
6566181 (6-12) - 540, 543 Loader Service Manual...395
  MAINTENANCE SAFETY...397
  CONTENTS...399
    FOREWORD...399
    SAFETY INSTRUCTIONS...401
  PREVENTIVE MAINTENANCE...403
    INTRODUCTION...405
      Serial Number Identification...405
      Loader Serial Number...405
      Engine Serial Number...405
      Pre–Delivery Inspection...405
      Thirty Hour Inspection...406
    SERVICE SCHEDULE...407
    ENGINE SERVICE (General)...408
      Air Cleaner Service...408
      Fuel System...409
      Engine Lubrication System...410
      Replacement Of The Engine Oil And Filter...410
      Engine Cooling System...411
    ELECTRICAL SYSTEM...412
      Electrical System Service...412
      Using An Extra Battery (Booster Starting)...412
      Installing New Battery...414
    HYDRAULIC/HYDROSTATIC FLUID...415
      Replacing The Hydraulic/Hydrostatic Filter...415
      Checking And Adding Hydraulic/Hydrostatic Fluid...415
      Removing The Hydraulic/Hydrostatic Fluid...416
    FINAL DRIVE TRANSMISSION (Chaincase)...417
      Checking Chaincase Fluid...417
    SPARK ARRESTOR MUFFLER...417
      Cleaning The Spark Arrestor Muffler...417
    OPERATOR GUARD...418
    LUBRICATION OF THE LOADER...418
    TRANSPORTING THE BOBCAT LOADER...419
      Loading The Bobcat Loader...419
      Fastening The Loader To TheTransport Vehicle...419
    LIFT ARM STOP...420
    STOPPING THE BOBCAT LOADER...420
  HYDRAULIC SYSTEM...421
    HYDRAULIC / HYDROSTATIC SCHEMATICS...423
    TROUBLESHOOTING...433
    HYDRAULIC SYSTEM INFORMATION...434
      37° Flare Connections...434
      Straight Thread O–Ring Fitting...434
      Tubelines and Hoses...434
    HYDRAULIC CONTROL VALVE...435
      Relief Valve...435
      Checking The Relief Valve...435
      Removal Of The Relief Valve...436
      Installation Of The Relief Valve...436
      Removal Of The Hydraulic Control Valve...437
      Disassembly Of The Hydraulic Control Valve...438
      Detent Mechanism...439
      Assembling the Hydraulic Control Valve...440
      Installing the Hydraulic Control Valve...442
    HYDRAULIC PUMP...442
      Checking Output Of The Hydraulic Pump...443
      Removal Of The Hydraulic Pump...443
      Disassembly Of The Hydraulic Pump...444
      Inspection Of The Hydraulic Pump...445
      Assembling The Hydraulic Pump...445
      Installing The Hydraulic Pump...447
      Start–Up Procedure For The Hydraulic Pump...447
    LIFT CYLINDERS...447
      Checking The Lift Cylinders...447
      Removing The Lift Cylinder...448
      Disassembly Of The Hydraulic Cylinder...449
      Assembly Of The Hydraulic Cylinder...450
      Installation Of The Lift Cylinder...452
    TILT CYLINDER...453
      Checking The Tilt Cylinder...453
      Removing The Tilt Cylinder...454
      Installation Of The Tilt Cylinder...455
    HYDRAULIC/HYDROSTATIC RESERVOIR...455
      Removing The Hydraulic/Hydrostatic Reservoir...455
      Installation Of The Hydraulic/Hydrostatic Reservoir...456
    OIL COOLER...456
      Removing The Oil Cooler (540)...456
      Installation Of The Oil Cooler (540)...457
      Removing The Oil Cooler (543)...457
      Installing The Oil Cooler (543)...458
    10 MICRON FILTER BY–PASSVALVE...458
      Removing The By–Pass Valve...458
      Installation Of The By–Pass Valve...459
      CONTROL PEDAL, LINKAGE AND LOCKS...459
      Removing The Control Pedal...459
      Adjusting The Control Pedal...460
      Pedal Lock Linkage...460
  HYDROSTATIC SYSTEM...463
    TROUBLESHOOTING...465
    HYDROSTATIC SYSTEM INFORMATION...466
      High Pressure Relief Replenishing Valves Function...466
    STEERING LEVERS...467
      Removing Steering Levers...467
      Repairing The Steering Levers...468
      Installing The Steering Levers...468
    STEERING LINKAGE...469
      Adjustment Of The Steering Linkage...469
      Removing The Steering Linkage...470
      Repairing The Pintle Lever...471
      Installing The Steering Linkage...471
    PORT BLOCK...472
      Removing The Port Block...472
      Installing The Port Block...472
      By–Pass Valve...473
    HYDROSTATIC MOTOR...473
      Removing The Hydrostatic Motor...473
      Disassembly Of The Hydrostatic Motor...475
      Inspection Of The Hydrostatic Motor...477
      Assembling The Hydrostatic Motor...478
      Installing The Hydrostatic Motor...481
      Start–Up Procedure For The Hydrostatic Motor...481
    HYDROSTATIC PUMP...482
      Checking The High Pressure Relief Replenishing Valves...482
      Checking The Charge Pressure...483
      Cold Weather By–Pass Valve...483
      Removing The Hydrostatic Pumps...484
      Disassembly Of The Hydrostatic Pumps...485
      Inspection Of The Hydrostatic Pumps...489
      Assembling The Hydrostatic Pumps...490
      Installing the Hydrostatic Pumps...493
      Hydrostatic Pump Start–Up Procedure...494
  DRIVE SYSTEM...497
    BRAKES...499
      Parking Brake Adjustment...499
      Parking Brake Removal...499
      Parking Brake Inspection...501
      Parking Brake Installation...501
    FINAL DRIVE CHAINS...503
      Remove The Drive Chain(s)...503
      Installing The Drive Chain(s)...504
    AXLES AND BEARINGS...505
      Removing Axle(s) and Bearings...505
      Assembly Of The Axle...506
      Axle And Bearing Installation...507
    CHAINCASE FLUID...508
      Replacing Chaincase Fluid...508
  MAIN FRAME...509
    OPERATOR GUARD...511
      Raising The Operator Guard...511
      Lowering The Operator Guard...511
      Jumper Start Switch...512
      Removing The Operator Guard...512
      Installing The Operator Guard...513
    LIFT ARMS...513
      Removing The Lift Arms...513
      Installing The Lift Arms...514
    BOB–TACH...515
      Removing The Bob–Tach...515
      Disassembly Of The Bob–Tach...516
      Assembly Of The Bob–Tach...517
      Installing The Bob–Tach...518
    REAR DOOR...519
      Removing The Rear Door (Early Model)...519
      Removing The Rear Door (Later Models)...519
      Installing The Rear Door...520
      Adjusting The Rear Door Latch...520
    FUEL TANK...521
      Removing The Fuel Tank...521
      Installing The Fuel Tank...521
  ELECTRICAL SYSTEM...523
    ELECTRICAL SCHEMATICS...526
    TROUBLESHOOTING...533
    ELECTRICAL SYSTEM INFORMATION...534
      Electrical Circuitry...534
      Safety Procedures For The Batteries...534
      Precautions For The Alternator...535
    BATTERY...535
      Removing The Battery...535
      Installing The Battery...536
    WIRE HARNESS FOR THE OPERATOR GUARD...536
      Removing The Wire Harness For The Operator Guard...536
      Installing The Wire Harness For The Operator Guard...537
    WIRE HARNESS FOR THE ENGINE...537
    ALTERNATOR SYSTEM (540)...538
      Checking the A.C. Voltage...538
      Replacement Of The Stator...538
    ALTERNATOR SYSTEM (543)...538
      Belt Adjustment For The Alternator...538
      Checking The Alternator...539
      Removing The Alternator...540
      Repairing The Alternator...541
      Installing The Alternator...542
    STARTER (540)...543
      Checking The Starter...543
      Removing The Starter...543
      Repairing The Starter...543
    STARTER (543)...544
      Checking The Starter...544
      Removing The Starter...544
      Repairing The Starter...545
      Installing The Starter...547
  ENGINE SERVICE...549
    540 KOHLER ENGINE SERVICE...551
      TROUBLESHOOTING...553
      CHECKS & ADJUSTMENTS...555
        Oil Pressure...555
        Valve Clearance...555
        Compression...556
        Throttle And Governor Linkage...556
        Ignition System...557
        Spark Plugs...557
      CARBURETOR & FUEL SHUT–OFF SOLENOID...558
        Removing The Carburetor...558
        Disassembly And Inspection Of The Carburetor...558
        Assembly Of The Carburetor...558
        Fuel Shut–off Solenoid...559
      GOVERNOR...559
        Removing The Governor...559
        Installing The Governor...559
      ENGINE AND HEAT SHIELD...560
        Removing The Engine...560
        Installation Of The Engine...561
        Removing The Heat Shield...561
        Installing The Heat Shield...562
      RECONDITIONING THE VALVES...562
        Repair Of The Valves And Guides...562
      TIMING COVER, TIMING GEARS AND CAMSHAFT...563
        Timing Cover...563
        Timing Gears...563
        Camshaft And Tappets...564
      OIL PUMP AND RELIEF VALVE...564
        Relief Valve...564
        Oil Pump...564
        Adjusting Gear Clearance For The Oil Pump...564
      PISTONS, RODS AND CRANKSHAFT...565
        Removing Pistons, Rods And Crankshaft...565
        Crankshaft Bearing And End Play...566
      CYLINDER HEAD...567
      INTAKE AND EXHAUST MANIFOLD...567
      FLYWHEEL...567
    543 ISUZU ENGINE SERVICE...569
      TROUBLESHOOTING...571
      FUEL SYSTEM...573
        Fuel Filter...573
        Removing The Air From The Fuel System...573
        Fuel Lift Pump...573
        Removal Of The Fuel Injection Pump...574
        Fuel Injection Pump Drive Gear...574
        Installation And Timing Of The Fuel Injection Pump...575
        Fuel Injection Pump Reservoir...575
        Fuel Injector Nozzles...576
        Removing The Fuel Injector Nozzles...576
        Checking The Fuel Injector Nozzles...577
        Disassembly Of The Fuel Injector Nozzle...578
        Inspection Of The Fuel Injector Nozzle...578
        Assembling The Fuel Injectors Nozzle...578
        nstallation Of The Fuel Injector Nozzles...579
      ENGINE, BLOWER HOUSING AND RADIATOR...579
        Removing The Engine...581
        Installing The Engine...582
        Installing The Blower Housing...583
        Removing The Radiator...584
        Installation Of The Radiator...586
      ENGINE OVERHAUL...587
        Disassembly Of The Engine...587
      ROCKER ARMS AND SHAFT...588
        Disassembly Of The Rocker Arms...588
        Inspection Of The Rocker Arms...589
      CYLINDER HEAD...589
        Disassembly Of The Cylinder Head...589
        Inspection Of The Cylinder Head...590
        Inspection Of The Combustion Chambers...590
        Inspection And Correction Of The Valves & Guides...590
        Inspection Of The Valve Springs...592
        Inspection Of The Push Rods And Tappets...592
        Installation Of The Hot Plugs...592
        Assembly Of The Valve System...592
      CYLINDER BLOCK...593
        Inspection Of The Cylinder Block...593
        Correction Of The Cylinder Bores...593
      PISTONS AND PISTON RINGS...593
        Disassembly Of The Piston And Rings...593
        Inspection Of The Pistons...594
        Inspection Of The Connecting Rods & Bearings...594
        Assembly Of The Piston & Connecting Rod...595
        Inspection Of The Connecting Rod Bearings...595
      CRANKSHAFT...596
        Inspection Of The Crankshaft And Bearings...596
      CAMSHAFT...596
        Inspection Of The Camshaft...596
      TIMING GEAR...597
        Inspection Of The Timing Gear...597
      MANIFOLD ASSEMBLY...597
        Inspection Of The Manifold Assembly...597
      OIL PUMP AND OIL FILTER ASSEMBLY...597
        Disassembly Of The Oil Pump...597
        Inspection Of The Oil Pump...598
        Oil Filter Assembly ...598
        Inspection Of The Oil Filter Assembly...598
       WATER PUMP ...598
        Disassembly Of The Water Pump...598
        Inspection Of The Water Pump...599
        Assembly Of The Water Pump...599
      ASSEMBLY OF THE ENGINE...600
      ENGINE FLYWHEEL...603
        Removing The Flywheel...603
        Installing The Flywheel...603
  TECHNICAL DATA...605
    540 LOADER SPECIFICATIONS...607
      Specifications...607
      Engine...607
      Loader Hydraulics...608
      Electrica...608
      Drive System...608
      Capacities...608
      Tires...608
    543 LOADER SPECIFICATIONS...609
      Specifications...609
      Engine...609
      Loader Hydraulics...610
      Electrical...610
      Drive System...610
      Capacities...610
      Tires...610
    ENGINE SPECIFICATIONS ...611
      540 LOADER (KOHLER)...611
        Engine (General)...611
        Cylinder Bore...611
        Crankshaft...611
        Camshaft...611
        Connecting Rod...611
        Piston, Pin & Rings...611
        Valves, Guides & Tappets...611
        Engine Torque...612
      543 LOADER (ISUZU)...613
        Cylinder Block...613
        Cylinder Head...613
        Piston...613
        Piston Ring...613
        Connecting Rod...613
        Crankshaft...613
        Camshaft...613
        Timing Gear...613
        Valve...614
        Valve Spring...614
        Tappet...614
        Oil Pump and Relief Valve...614
        Water Pump...614
        Fuel Lift Pump...614
        Fuel Injector...614
        Engine Torque...615
      TORQUE SPECIFICATIONS...616
        Engine Group – 540 Loader...616
        Engine Group – 543 Loader...617
        Engine Group – 543 Loader...618
        Seat Bar, Fuel Tank & Panel Group...619
        Steering Levers, Linkage & Pedal Group...620
        Mainframe Group...622
        Hydrostatic Group – 540 Loader...623
        Hydrostatic Group – 543 Loader...624
        Hydraulic Group...625
      HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...626
        Hydraulic/Hydrostatic Fluid...626
      DECIMAL AND MILLIMETER EQUIVALENTS...627
      U.S. TO METRIC CONVERSION...627
      STANDARD TORQUE SPECIFICATIONS FOR BOLTS...628
  ALPHABETICAL INDEX...629
  SERVICE MANUAL REVISIONS...635
    540–1...635
    540–2...637
    540–2...639
    540–3...641
    540–4...643
    540–5...645
    540–6...647
    540-7...649
6566276 (9-96) - 543 Operation & Maintenance Manual...651
  SAFETY INSTRUCTIONS...655
    SAFETY IS THE OPERATOR& RESPONSIBILITY...655
    BEFORE YOU OPERATE THE BOBCAT LOADER...655
    SERIAL NUMBER IDENTIFICATION...656
      Loader Serial Number...656
      Engine Serial Number...656
  FOREWORD...657
    CONTENTS...657
    REFERENCE INFORMATION...657
    543 BOBCAT LOADER IDENTIFICATION...658
  OPERATING INSTRUCTIONS...659
    OPERATING INSTRUCTIONS...661
    CONTROLS...662
    DASH PANEL...665
    THROTTLE CONTROL...665
    TO STOP THE ENGINE...665
    PARKING BRAKE...665
    STEERING LEVERS...666
    HYDRAULIC CONTROLS...667
      Foot Pedals (Hydraulic)...667
      Lift Arm Operation...667
      Float Position...667
      Tilt (Bucket) Operation...667
      Auxiliary Lever Operation...668
    BEFORE YOU START THE ENGINE...669
    STARTING THE ENGINE...670
      Normal Starting Condition...671
      Cold Temperature Starting Condition...671
    ATTACHMENTS & BUCKETS ...672
      Installation Of Attachments...673
      Removal Of Attachments...674
    OPERATING PROCEDURE...674
      Filling The Bucket...675
      To Empty The Bucket...675
      Digging Into The Ground...676
      Making The Ground Level Using Float Position...676
      Filling A Hole...676
    PARKING THE BOBCAT LOADER...677
    TRANSPORTING THE BOBCAT LOADER...677
    LIFT ARM SUPPORT DEVICE...678
    LIFTING THE OPERATOR GUARD...678
    LOWERING THE OPERATOR CAB...679
    LIFTING THE BOBCAT LOADER...680
  PREVENTIVE MAINTENANCE...681
    SERVICE SCHEDULE...683
    ENGINE SERVICE...684
    ADJUSTING THE DOOR LATCH...684
    AIR CLEANER SERVICE...684
    FUEL SYSTEM...685
    FUEL SYSTEM SERVICE...685
    FUEL FILTER...685
    REMOVING WATER FROM THE FUEL SYSTEM...686
    REMOVING AIR FROM THE FUEL SYSTEM...686
    ENGINE LUBRICATION SYSTEM...686
    REPLACEMENT OF ENGINE OIL AND FILTER...687
    COOLANT LEVEL...688
    REMOVING COOLANT FROM THE COOLING SYSTEM...688
    ALTERNATOR BELT...688
    ELECTRICAL SYSTEM...691
    USING AN EXTRA BATTERY (JUMP STARTING)...691
    TO INSTALL A NEW BATTERY...692
    SPARK ARRESTOR MUFFLER...693
    HYDRAULIC / HYDROSTATIC SYSTEM...693
    REPLACEMENT OF THE HYDRAULIC FILTER ELEMENT...695
    HYDRAULIC / HYDROSTATIC FLUID RESERVOIR...695
      Checking And Adding Fluid...695
      Removing The Hydraulic / Hydrostatic Fluid...696
    FINAL DRIVE TRANSMISSION (CHAINCASE)...696
    TIRE MAINTENANCE...696
      Tire Rotation...697
      wheel Nuts...697
    LUBRICATION OF THE BOBCAT LOADER...697
    ROLL OVER PROTECTIVE STRUCTURE (ROPS & FOPS)...698
    BOB-TACH...698
    PIVOT PINS...699
    BRAKE PEDAL ADJUSTMENT...699
    DELIVERY REPORT...699
  TROUBLESHOOTING...701
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...703
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM...704
    TROUBLESHOOTING THE ENGINE...705
  MAJOR PARTS...707
    MAIN FRAME...708
    PANELS, SEAT, SEAT BAR & FUEL SYSTEM...709
    BRAKES, CHAINCASE & AXLE...710
    HYDRAULIC SYSTEM...711
    HYDROSTATIC SYSTEM...712
    STEERING CONTROLS...713
    OPERATOR CAB ELECTRICAL SYSTEM...714
    LIFT ARMS, BOB-TACH & CONTROL PEDALS...715
    ENGINE ELECTRICAL SYSTEM...716
    ENGINE & ATTACHING PARTS...717
  WARNING SIGNS...719
    WARNING SIGNS (DECALS)...720
    WARNING - 6563484...721
    SERVICE SCHEDULE - 6565318...722
    WARNING - 6563380...724
    WARNING - 6561380...725
    IMPORTANT - 6560573...726
  GENERAL INFORMATION...727
    LOADER SPECIFICATIONS...729
      Operation & Performance...729
      Pallet Fork Weight Distribution Specifications...729
      Engine...729
      Loader Hydraulics...730
      Electrical...730
      Drive System...730
      Capactities...730
      Tires...730
    ADDITIONAL PUBLICATIONS...731
  WARRANTY...733
6566282 (11-82) - 540 Loader Operator& Manual...735
  SAFETY INSTRUCTIONS...737
    SAFETY IS YOUR RESPONSIBILITY...737
    BEFORE YOU OPERATE THE BOBCAT LOADER...737
    SERIAL NUMBER IDENTIFICATION...738
      Loader Serial Number...738
      Engine Serial Number...738
  FOREWORD...739
    CONTENTS...739
    REFERENCE INFORMATION...739
    540 BOBCAT LOADER IDENTIFICATION...740
  OPERATING INSTRUCTIONS...741
    OPERATING INSTRUCTIONS...743
    CONTROLS...744
    DASH PANEL...747
    THROTTLE CONTROL...747
    CHOKE CONTROL...747
    PARKING BRAKE...747
    TO STOP THE ENGINE...748
    STEERING LEVERS...748
    HYDRAULIC CONTROLS...749
      Foot Pedals (Hydraulic)...749
      Lift Arm Operation...749
      Float Position...749
      Tilt (Bucket) Operation...749
      Auxiliary Lever Operation...750
    BEFORE YOU START THE ENGINE...751
    STARTING THE ENGINE...752
      Normal Starting Condition...753
      Cold Temperature Starting Condition...753
    ATTACHMENTS & BUCKETS ...754
      Installation Of Attachments...755
      Removal Of Attachments...755
    OPERATING PROCEDURE...756
      Filling The Bucket...756
      To Empty The Bucket...757
      Digging Into The Ground...758
      Making The Ground Level Using Float Position...758
      Filling A Hole...758
    PARKING THE BOBCAT LOADER...759
    TRANSPORTING THE BOBCAT LOADER...759
    LIFT ARM STOP...760
    LIFTING THE OPERATOR CAB...760
    LOWERING THE OPERATOR CAB...761
    LIFTING THE BOBCAT LOADER...762
  PREVENTIVE MAINTENANCE...763
    SERVICE SCHEDULE...765
    ENGINE SERVICE...766
    ADJUSTING THE DOOR LATCH...766
    AIR CLEANER SERVICE...766
    FUEL SYSTEM...767
    FUEL SYSTEM SERVICE...767
    FUEL FILTER...767
    ENGINE LUBRICATION SYSTEM...768
    REPLACEMENT OF THE ENGINE OIL AND FILTER...768
    ENGINE COOLING SYSTEM...769
    ELECTRICAL SYSTEM...769
    USING AND EXTRA BATTERY (JUMP STARTING)...772
    TO INSTALL A NEW BATTERY...773
    SPARK ARRESTOR MUFFLER...774
    HYDRAULIC / HYDROSTATIC SYSTEM...774
    REPLACEMENT OF THE HYDRAULIC FILTER ELEMENT...776
    HYDRAULIC / HYDROSTATIC FLUID RESERVOIR...776
      Checking And Adding Fluid...776
      Removing The Hydraulic / Hydrostatic Fluid...777
    FINAL DRIVE TRANSMISSION (CHAINCASE)...777
    TIRE MAINTENANCE...778
      Tire Rotation...778
      Wheel Nuts...778
    LUBRICATION OF THE BOBCAT LOADER...778
    ROLL OVER & FALLING OBJECT PROTECTIVE STRUCTURE (ROPS & FOPS)...779
    BOB-TACH...779
    PIVOT PINS...780
    BRAKE PEDAL ADJUSTMENT...780
    DELIVERY REPORT...781
  TROUBLESHOOTING...783
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...785
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM...786
    TROUBLESHOOTING THE ENGINE...787
  MAJOR PARTS...789
    MAIN FRAME...791
    PANELS, SEAT, SEAT BAR & FUEL SYSTEM...792
    BRAKES, CHAINCASE & AXLE...793
    HYDRAULIC SYSTEM...794
    HYDROSTATIC SYSTEM...795
    STEERING CONTROLS...796
    OPERATOR CAB ELECTRICAL SYSTEM...797
    LIFT ARMS, BOB-TACH & CONTROL PEDALS...798
    ENGINE ELECTRICAL SYSTEM...799
    ENGINE & ATTACHING PARTS...800
  WARNING SIGNS...801
    WARNING SIGNS (DECALS)...802
    WARNING - 6563484...803
    SERVICE SCHEDULE - 6565318...804
    WARNING - 6563380...806
    WARNING - 6561380...807
    IMPORTANT - 6560573...808
  GENERAL INFORMATION...809
    540 LOADER SPECIFICATIONS...811
      Operation & Performance...811
      Engine...811
      Loader Hydraulics...812
      Electrical...812
      Drive System...812
      Capacities...812
      Tires...812
  WARRANTY...813
6566532 (11-94) - 540, 543, 543B Loader Service Manual...815
  MAINTENANCE SAFETY...817
  ALPHABETICAL INDEX...819
  CONTENTS...821
    FOREWORD...823
    SAFETY INSTRUCTIONS...825
  PREVENTIVE MAINTENANCE...827
    INTRODUCTION...829
      Serial Number Identification...829
      Loader Serial Number...829
      Engine Serial Number...829
       Delivery Report...829
    SERVICE SCHEDULE...830
    ENGINE SERVICE (General)...831
      Air Cleaner Service (540)...831
      Air Cleaner Service (543)...832
      Fuel System...833
      Replacement of the Engine Oil and Filter...834
      Engine Cooling System (540)...837
      Engine Cooling System (543)...838
    ELECTRICAL SYSTEM...839
      Electrical System Service...839
      Using an Extra Battery (Booster Starting)...839
       Installing New Battery...841
    SPARK ARRESTOR MUFFLER...842
    HYDRAULIC/HYDROSTATIC SYSTEM...843
      Replacing The Hydraulic Filter Element...843
      Checking & Adding Hydraulic/HydrostaticFluid...844
      Removing The Hydraulic/Hydrostatic Fluid...846
    FINAL DRIVE TRANSMISSION (CHAINCASE)...846
      Checking/Adding Chaincase Fluid...846
    TIRE MAINTENANCE...847
      Tire Rotation...847
      Wheel Nuts...847
    LUBRICATION OF THE LOADER...848
      Lubrication Of The Loader...848
    ROLL OVER PROTECTION STRUCTURE (ROPS & FOPS)...848
      Operator Cab...848
    TRANSPORTING THE BOBCAT LOADER...849
      Loading The Bobcat Loader...849
      Fastening The Loader To The Transport Vehicle...849
      Lifting The Loader...850
      Towing The Loader...850
    LIFT ARM SUPPORT DEVICE...851
      Installing the Approved Lift Arm Support Device...851
    STOPPING THE BOBCAT LOADER...851
  HYDRAULIC SYSTEM...853
    HYDRAULIC / HYDROSTATIC SCHEMATICS...855
    TROUBLESHOOTING...863
    HYDRAULIC SYSTEM INFORMATION...864
      37° Flare Connections...864
      Straight Thread O–Ring Fitting...864
      Tubelines And Hoses...864
    HYDRAULIC CONTROL VALVE...865
      Relief Valve...865
      Check The Relief Valve...865
      Removal Of The Relief Valve...866
      Installation Of The Relief Valve...866
      Removal Of The Hydraulic Control Valve...867
      Disassembly Of The Hydraulic Control Valve...868
      Detent Mechanism...869
      Assembling The Hydraulic Control Valve...870
      Installing The Hydraulic Control Valve...872
    HYDRAULIC CONTROL VALVE (MELROE)...873
      Relief Valve...873
      Check The Relief Valve...873
      Adjusting The Relief Valve...874
      Relief Valve Service...874
      Installation Of A New Relief Valve...875
      Removal Of The Hydraulic Control Valve (Melroe)...875
      Disassembly Of The Control Valve...876
      Inspection Of The Control Valve...878
      Assembly Of The Control Valve...879
      Installation Of The Control Valve...881
    HYDRAULIC PUMP...881
      Checking Output Of Hydraulic Pump...883
      Removal Of The Hydraulic Pump...883
      Disassembly Of The Hydraulic Pump...884
      Inspection Of The Hydraulic Pump...885
      Assembling The Hydraulic Pump...885
      Installation To The Hydraulic Pump...886
      Start–up Procedure For The Hydraulic Pump...886
    LIFT CYLINDERS...887
      Checking The Lift Cylinders...887
      Removing The Lift Cylinder...887
      Disassembly Of The Hydraulic Cylinder...888
      Assembly Of The Hydraulic Cylinder ...889
      Installation Of The Lift Cylinder...891
    TILT CYLINDER...892
      Checking The Tilt Cylinder...892
      Removing The Tilt Cylinder...893
      Installation Of The Tilt Cylinder...894
    HYDRAULIC/HYDROSTATIC RESERVOIR...894
      Removing The Hydraulic/Hydrostatic Reservoir...894
      Installation Of The Hydraulic/Hydrostatic Reservoir...895
    OIL COOLER...895
      Removing The Oil Cooler (540)...895
      Installation Of The Oil Cooler (540)...896
      Removing The Oil Cooler (543)...896
      Installation Of The Oil Cooler (543)...896
    10 MICRON FILTER BY–PASS VALVE...896
      Remove The By–Pass Valve...896
      Installation Of The By–Pass Valve...897
    CONTROL PEDAL, LINKAGE AND LOCKS...897
      Removing The Control Pedal...897
      Installation Of The Control Pedal...897
      Adjusting The Control Pedal...898
      Pedal Lock Linkage...898
  HYDROSTATIC SYSTEM...901
    TROUBLESHOOTING...903
    HYDROSTATIC SYSTEM INFORMATION...904
      High Pressure Relief Replenishing Valves Function...904
    STEERING LEVERS...905
      Removing Steering Levers...905
      Repairing The Steering Levers...906
      Installing The Steering Levers...906
    STEERING LINKAGE...907
      Adjustment Of The Steering Linkage...907
      Removing The Steering Linkage...908
      Repairing The Pintle Lever...909
      Installing The Steering Linkage...909
    PORT BLOCK...910
      Removing The Port Block...910
      Installing The Port Block...910
      By–Pass Valve...911
      Charge By–Pass Valve...911
    HYDROSTATIC MOTOR...911
      Removing The Hydrostatic Motor...912
        Motors With Keyed–Shaft...912
        Motors With Splined–Shaft...912
      Disassembly of the Hydrostatic Motor...913
      Hydrostatic Motor Inspection...916
      Assembly Of The Hydrostatic Motor...917
      Installing The Hydrostatic Motor...923
        Keyed–Shaft Motors...923
        Splined–Shaft Motors...923
      Start–Up Procedure For The Hydrostatic Motor...923
    HYDROSTATIC PUMP...924
      Checking The High Pressure Relief Replenishing Valves...924
      Checking The Charge Pressure...925
      Removing The Hydrostatic Pump...925
      Disassembly Of The Hydrostatic Pump...927
      Inspection Of The Hydrostatic Pumps...930
      Assembling The Hydrostatic Pumps...931
      Installing The Hydrostatic Pumps...934
      Start–Up Procedure For The Hydrostatic Pump...936
    TOWING THE BOBCAT LOADER...938
      Installation Of The Tool For The High Pressure Relief Valves...938
  DRIVE SYSTEM...939
    PARKING BRAKE...941
      Parking Brake Adjustment...941
      Parking Brake Removal...942
      Parking Brake Inspection...945
      Parking Brake Installation...945
    FINAL DRIVE CHAINS...949
      Remove The Drive Chain(s)...949
      Installing The Drive Chain(s)...950
    AXLES AND BEARINGS...951
      Removing Axle(s) and Bearings...951
      Assembly Of The Axle...952
      Axle And Bearing Installation...953
    CHAINCASE FLUID...954
      Replacing Chaincase Fluid...954
  MAIN FRAME...955
    OPERATOR CAB...957
      Raising The Operator Cab...957
      Lowering The Operator Cab...958
      Jumper Start Switch...959
      Removing The Operator Cab...960
      Removing The Gas Cylinder...961
      Installing The Operator Cab...963
    LIFT ARMS...963
      Removing The Lift Arms...963
      Installing The Lift Arms...964
    BOB–TACH...965
      Removing The Bob–Tach...965
      Disassembly Of The Bob–Tach...966
      Assembly Of The Bob–Tach...967
      Installing The Bob–Tach...968
    REAR DOOR...969
      Removing The Rear Door...969
      Installing The Rear Door...970
      Adjusting The Rear Door Latch...970
    FUEL TANK...970
      Removing The Fuel Tank...970
      Installing The Fuel Tank...971
    SEAT BAR...971
      Removal And Installation...971
    SEAT BAR SYSTEM...972
      Seat Bar Inspection...972
      Seat Bar Maintenance...972
    PEDAL LOCK LINKAGE...973
      Adjustment...973
    REAR WINDOW...973
      Installing Rear Window...973
  ELECTRICAL SYSTEM...975
    ELECTRICAL SCHEMATICS...978
    TROUBLESHOOTING...991
    ELECTRICAL SYSTEM INFORMATION...992
      Electrical Circuitry...992
      Safety Procedures For The Batteries...992
      Precautions For The Alternator...993
    BATTERY...993
      Removing The Battery...993
      Installing The Battery...994
    WIRE HARNESS FOR THE OPERATOR CAB...994
      Removing The Wire Harness For The Operator Cab...994
      Installing The Wire Harness For The Operator Cab...995
    WIRE HARNESS FOR THE ENGINE...995
     ALTERNATOR SYSTEM (540)...996
      Checking The Alternator...996
      Replacing The Stator...998
    ALTERNATOR SYSTEM (543)...998
      Adjusting The Alternator Belt...998
      Alternator Output Test (New Style)...1000
      Rectifier (Diode) Test (New Style)...1000
      Alternator Regulator Test (New Style)...1001
      Checking The Alternator (Early Models)...1003
      Parts Identification (New Style)...1005
      Disassembly And Assembly (New Style)...1005
      Stator Continuity Test...1005
      Stator Ground Test...1005
      Rotor Continuity Test...1006
      Rotor Ground Test...1006
      Rectifier Continuity (Diode) Test...1006
      Removing The Alternator (Early Models)...1009
      Repairing The Alternator (Early Models)...1009
      Installing The Alternator (Early Models)...1010
    STARTER (540)...1011
      Checking The Starter...1011
      Removing The Starter...1011
      Repairing The Starter...1011
    STARTER (543)...1012
      Checking The Starter...1012
      Removing The Starter...1012
      Repairing The Starter...1013
      Installing The Starter...1016
  ENGINE SERVICE...1017
    ENGINE SERVICE (540) KOHLER...1019
      TROUBLESHOOTING...1021
      CHECKS AND ADJUSTMENTS FOR THE ENGINE...1023
        Engine Oil Pressure...1023
        Valve Clearance...1023
        Compression...1024
        Throttle And Governor Linkage...1024
        Ignition System...1025
        Spark Plugs...1025
      CARBURETOR & FUELSHUT–OFF SOLENOID...1026
        Removing The Carburetor...1026
        Disassembly And Inspection Of The Carburetor ...1026
        Assembly Of The Carburetor...1026
        Fuel Shut–off Solenoid...1027
        Non–Metallic Bodied Fuel Pumps...1027
      GOVERNOR...1027
        Removing The Governor...1027
        Installing The Governor...1027
      ENGINE AND HEAT SHIELD...1028
        Removing The Engine...1028
        Installing The Engine...1029
        Removing The Heat Shield...1030
        Installing The Heat Shield...1030
      RECONDITIONING THEVALVES...1031
        Repair Of The Valves And Guides...1031
      TIMING COVER, TIMING GEARS AND CAMSHAFT...1032
        Timing Cover...1032
        Timing Gears...1032
        Camshaft And Tappets...1032
      OIL PUMP AND RELIEF VALVE...1032
        Relief Valve...1032
        Oil Pump...1033
        Adjusting Gear Clearance For The Oil Pump...1033
      PISTONS, RODS AND CRANKSHAFT...1034
        Removing Pistons, Rods And Crankshaft...1034
        Crankshaft Bearing And End Play...1034
      CYLINDER HEAD...1035
      INTAKE AND EXHAUST MANIFOLD...1036
      FLYWHEEL...1036
    ENGINE SERVICE (543 & 543B) KUBOTA...1037
      TROUBLESHOOTING...1039
      FUEL SYSTEM...1041
        Replacing The Fuel Filter...1041
        To Remove The Air From The Fuel System...1041
        Fuel Injection Pump...1042
        Checking The Injection Pump...1042
        Installation...1045
        Timing The Fuel Injection Pump...1045
        Fuel Injector Nozzles...1046
        Removal...1046
        Checking The Fuel Injector Nozzles...1047
        Installation...1049
        Checking Glow Plugs...1049
      ENGINE AND ATTACHING PARTS...1049
        Removing The Engine...1049
        Installing The Engine...1053
        Engine Muffler...1054
        Engine Radiator Removal...1055
        Engine Radiator Installation...1057
        Engine Blower Housing Removal...1058
        Engine Blower Housing Installation...1059
        Engine Blower Fan And Flywheel Removal...1059
        Engine Blower Fan And Flywheel Installation...1059
      CYLINDER HEAD...1060
        Removing The Cylinder Head...1060
        Disassembly Of The Cylinder Head...1061
        Servicing The Cylinder Head...1061
         Assembly Of The Cylinder Head...1063
        Installing The Cylinder Head...1063
        Adjusting the Compression Release Mechanism...1064
      REPAIRING THE ENGINE...1065
        Removing The Gear Case...1065
        Removing The Timing Gear, Camshaft & Oil Pump...1066
        Removing Pistons And Crankshaft...1067
        Servicing The Timing Gear And The Camshaft...1068
        Servicing The Connecting Rods And Pistons...1069
        Servicing The Crankshaft...1070
        Servicing The Cylinder Liners...1071
        Servicing The Oil Pump...1072
        Servicing The Water Pump...1073
      ASSEMBLY OF THE ENGINE...1073
        Installing The Crankshaft...1073
        Installing The Pistons...1073
        Installing The Camshaft And Timing Gears...1074
        Installing The Gear Case Cover...1075
  TECHNICAL DATA...1077
    (540) KOHLER LOADER SPECIFICATIONS...1079
      Operation & Performance...1079
      Engine...1079
      Loader Hydraulics...1080
      Electrical...1080
      Drive System...1080
      Capacities...1080
      Tires...1080
    ENGINE SPECIFICATIONS – 540 LOADER (KOHLER)...1081
      Engine (General)...1081
      Cylinder Bore...1081
      Crankshaft...1081
      Camshaft...1081
      Connecting Rod...1081
      Piston, Pin And Rings...1081
      Valves, Guides & Tappets...1082
      Engine Torque...1082
    543 & 543B KUBOTA LOADER SPECIFICATIONS...1083
      Operation & Performance...1083
      Engine...1083
      Loader Hydraulics...1084
      Electrical...1084
      Drive System...1084
      Capacities...1084
      Tires ...1084
    ENGINE SPECIFICATIONS - 543-543B LOADER...1085
      Fuel Injector Nozzles...1085
      Fuel Injection Pump...1085
      Cylinder Head...1085
      Valves...1085
      Valve Springs...1085
      Rocker Arms...1085
      Camshaft...1085
      Cylinders...1086
      Piston Rings...1086
      Piston...1086
      Crankshaft...1086
      Oil Pump...1086
      Thermostat...1086
      Engine Torque...1087
      Grinding Specifications for the Crankshaft...1088
    TORQUE SPECIFICATIONS...1089
      Engine Group – 540 Loader...1089
      Engine Group – 543 Loader...1090
      Fuel System Group...1092
      Steering Levers & Panel Group...1093
      Bob–Tach & Lift Arm Group...1094
      Seat Bar & Pedal Group...1095
      Brake, Chaincase & Axle Group...1096
      Hydraulic Group...1097
      Operator Cab, Main Frame & Rear Door Group...1098
      Hydrostatic Group–540 Loader...1099
      Hydrostatic Group–543 Loader...1100
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...1101
      Hydraulic/Hydrostatic Fluid...1101
    DECIMAL AND MILLIMETER EQUIVALENTS...1102
    U.S. TO METRIC CONVERSION...1102
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...1103
  SERVICE MANUAL REVISIONS...1105
    540–3...1105
    540–4...1107
    540–5...1109
    540–6...1111
    540–7...1113
    540–8...1115
    540–9...1117
    540–11...1119
    540–13...1121
    540–14...1123
    540–15...1125
    540–16...1127
    540–17...1129
    540–1 Thru 540–17...1131
    540–18...1133
    540–19...1135
6566532 (6-12) - 540, 543, 543B Loader Service Manual...1137
  MAINTENANCE SAFETY...1139
  ALPHABETICAL INDEX...1141
  CONTENTS...1143
    FOREWORD...1145
    SAFETY INSTRUCTIONS...1147
  PREVENTIVE MAINTENANCE...1149
    INTRODUCTION...1151
      Serial Number Identification...1151
      Loader Serial Number...1151
      Engine Serial Number...1151
       Delivery Report...1151
    SERVICE SCHEDULE...1152
    ENGINE SERVICE (General)...1153
      Air Cleaner Service (540)...1153
      Air Cleaner Service (543)...1154
      Fuel System...1155
      Replacement of the Engine Oil and Filter...1156
      Engine Cooling System (540)...1159
      Engine Cooling System (543)...1160
    ELECTRICAL SYSTEM...1161
      Electrical System Service...1161
      Using an Extra Battery (Booster Starting)...1161
       Installing New Battery...1163
    SPARK ARRESTOR MUFFLER...1164
    HYDRAULIC/HYDROSTATIC SYSTEM...1165
      Replacing The Hydraulic Filter Element...1165
      Checking & Adding Hydraulic/HydrostaticFluid...1166
      Removing The Hydraulic/Hydrostatic Fluid...1168
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1168
      Checking/Adding Chaincase Fluid...1168
    TIRE MAINTENANCE...1169
      Tire Rotation...1169
      Wheel Nuts...1169
    LUBRICATION OF THE LOADER...1170
      Lubrication Of The Loader...1170
    ROLL OVER PROTECTION STRUCTURE (ROPS & FOPS)...1170
      Operator Cab...1170
    TRANSPORTING THE BOBCAT LOADER...1171
      Loading The Bobcat Loader...1171
      Fastening The Loader To The Transport Vehicle...1171
      Lifting The Loader...1172
      Towing The Loader...1172
    LIFT ARM SUPPORT DEVICE...1173
      Installing the Approved Lift Arm Support Device...1173
    STOPPING THE BOBCAT LOADER...1173
  HYDRAULIC SYSTEM...1175
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1177
    TROUBLESHOOTING...1185
    HYDRAULIC SYSTEM INFORMATION...1186
      37° Flare Connections...1186
      Straight Thread O–Ring Fitting...1186
      Tubelines And Hoses...1186
    HYDRAULIC CONTROL VALVE...1187
      Relief Valve...1187
      Check The Relief Valve...1187
      Removal Of The Relief Valve...1188
      Installation Of The Relief Valve...1188
      Removal Of The Hydraulic Control Valve...1189
      Disassembly Of The Hydraulic Control Valve...1190
      Detent Mechanism...1191
      Assembling The Hydraulic Control Valve...1192
      Installing The Hydraulic Control Valve...1194
    HYDRAULIC CONTROL VALVE (MELROE)...1195
      Relief Valve...1195
      Check The Relief Valve...1195
      Adjusting The Relief Valve...1196
      Relief Valve Service...1196
      Installation Of A New Relief Valve...1197
      Removal Of The Hydraulic Control Valve (Melroe)...1197
      Disassembly Of The Control Valve...1198
      Inspection Of The Control Valve...1200
      Assembly Of The Control Valve...1201
      Installation Of The Control Valve...1203
    HYDRAULIC PUMP...1203
      Checking Output Of Hydraulic Pump...1205
      Removal Of The Hydraulic Pump...1205
      Disassembly Of The Hydraulic Pump...1206
      Inspection Of The Hydraulic Pump...1207
      Assembling The Hydraulic Pump...1207
      Installation To The Hydraulic Pump...1208
      Start–up Procedure For The Hydraulic Pump...1208
    LIFT CYLINDERS...1209
      Checking The Lift Cylinders...1209
      Removing The Lift Cylinder...1209
      Disassembly Of The Hydraulic Cylinder...1210
      Assembly Of The Hydraulic Cylinder ...1211
      Installation Of The Lift Cylinder...1213
    TILT CYLINDER...1214
      Checking The Tilt Cylinder...1214
      Removing The Tilt Cylinder...1215
      Installation Of The Tilt Cylinder...1216
    HYDRAULIC/HYDROSTATIC RESERVOIR...1216
      Removing The Hydraulic/Hydrostatic Reservoir...1216
      Installation Of The Hydraulic/Hydrostatic Reservoir...1217
    OIL COOLER...1217
      Removing The Oil Cooler (540)...1217
      Installation Of The Oil Cooler (540)...1218
      Removing The Oil Cooler (543)...1218
      Installation Of The Oil Cooler (543)...1218
    10 MICRON FILTER BY–PASS VALVE...1218
      Remove The By–Pass Valve...1218
      Installation Of The By–Pass Valve...1219
    CONTROL PEDAL, LINKAGE AND LOCKS...1219
      Removing The Control Pedal...1219
      Installation Of The Control Pedal...1219
      Adjusting The Control Pedal...1220
      Pedal Lock Linkage...1220
  HYDROSTATIC SYSTEM...1223
    TROUBLESHOOTING...1225
    HYDROSTATIC SYSTEM INFORMATION...1226
      High Pressure Relief Replenishing Valves Function...1226
    STEERING LEVERS...1227
      Removing Steering Levers...1227
      Repairing The Steering Levers...1228
      Installing The Steering Levers...1228
    STEERING LINKAGE...1229
      Adjustment Of The Steering Linkage...1229
      Removing The Steering Linkage...1230
      Repairing The Pintle Lever...1231
      Installing The Steering Linkage...1231
    PORT BLOCK...1232
      Removing The Port Block...1232
      Installing The Port Block...1232
      By–Pass Valve...1233
      Charge By–Pass Valve...1233
    HYDROSTATIC MOTOR...1233
      Removing The Hydrostatic Motor...1234
        Motors With Keyed–Shaft...1234
        Motors With Splined–Shaft...1234
      Disassembly of the Hydrostatic Motor...1235
      Hydrostatic Motor Inspection...1238
      Assembly Of The Hydrostatic Motor...1239
      Installing The Hydrostatic Motor...1245
        Keyed–Shaft Motors...1245
        Splined–Shaft Motors...1245
      Start–Up Procedure For The Hydrostatic Motor...1245
    HYDROSTATIC PUMP...1246
      Checking The High Pressure Relief Replenishing Valves...1246
      Checking The Charge Pressure...1247
      Removing The Hydrostatic Pump...1247
      Disassembly Of The Hydrostatic Pump...1249
      Inspection Of The Hydrostatic Pumps...1252
      Assembling The Hydrostatic Pumps...1253
      Installing The Hydrostatic Pumps...1256
      Start–Up Procedure For The Hydrostatic Pump...1258
    TOWING THE BOBCAT LOADER...1260
      Installation Of The Tool For The High Pressure Relief Valves...1260
  DRIVE SYSTEM...1261
    PARKING BRAKE...1263
      Parking Brake Adjustment...1263
      Parking Brake Removal...1264
      Parking Brake Inspection...1267
      Parking Brake Installation...1267
    FINAL DRIVE CHAINS...1271
      Remove The Drive Chain(s)...1271
      Installing The Drive Chain(s)...1272
    AXLES AND BEARINGS...1273
      Removing Axle(s) and Bearings...1273
      Assembly Of The Axle...1274
      Axle And Bearing Installation...1275
    CHAINCASE FLUID...1276
      Replacing Chaincase Fluid...1276
  MAIN FRAME...1277
    OPERATOR CAB...1279
      Raising The Operator Cab...1279
      Lowering The Operator Cab...1280
      Jumper Start Switch...1281
      Removing The Operator Cab...1282
      Removing The Gas Cylinder...1283
      Installing The Operator Cab...1285
    LIFT ARMS...1285
      Removing The Lift Arms...1285
      Installing The Lift Arms...1286
    BOB–TACH...1287
      Removing The Bob–Tach...1287
      Disassembly Of The Bob–Tach...1288
      Assembly Of The Bob–Tach...1289
      Installing The Bob–Tach...1290
    REAR DOOR...1291
      Removing The Rear Door...1291
      Installing The Rear Door...1292
      Adjusting The Rear Door Latch...1292
    FUEL TANK...1292
      Removing The Fuel Tank...1292
      Installing The Fuel Tank...1293
    SEAT BAR...1293
      Removal And Installation...1293
    SEAT BAR SYSTEM...1294
      Seat Bar Inspection...1294
      Seat Bar Maintenance...1294
    PEDAL LOCK LINKAGE...1295
      Adjustment...1295
    REAR WINDOW...1295
      Installing Rear Window...1295
  ELECTRICAL SYSTEM...1297
    ELECTRICAL SCHEMATICS...1300
    TROUBLESHOOTING...1313
    ELECTRICAL SYSTEM INFORMATION...1314
      Electrical Circuitry...1314
      Safety Procedures For The Batteries...1314
      Precautions For The Alternator...1315
    BATTERY...1315
      Removing The Battery...1315
      Installing The Battery...1316
    WIRE HARNESS FOR THE OPERATOR CAB...1316
      Removing The Wire Harness For The Operator Cab...1316
      Installing The Wire Harness For The Operator Cab...1317
    WIRE HARNESS FOR THE ENGINE...1317
     ALTERNATOR SYSTEM (540)...1318
      Checking The Alternator...1318
      Replacing The Stator...1320
    ALTERNATOR SYSTEM (543)...1320
      Adjusting The Alternator Belt...1320
      Alternator Output Test (New Style)...1322
      Rectifier (Diode) Test (New Style)...1322
      Alternator Regulator Test (New Style)...1323
      Checking The Alternator (Early Models)...1325
      Parts Identification (New Style)...1327
      Disassembly And Assembly (New Style)...1327
      Stator Continuity Test...1327
      Stator Ground Test...1327
      Rotor Continuity Test...1328
      Rotor Ground Test...1328
      Rectifier Continuity (Diode) Test...1328
      Removing The Alternator (Early Models)...1331
      Repairing The Alternator (Early Models)...1331
      Installing The Alternator (Early Models)...1332
    STARTER (540)...1333
      Checking The Starter...1333
      Removing The Starter...1333
      Repairing The Starter...1333
    STARTER (543)...1334
      Checking The Starter...1334
      Removing The Starter...1334
      Repairing The Starter...1335
      Installing The Starter...1338
  ENGINE SERVICE...1339
    ENGINE SERVICE (540) KOHLER...1341
      TROUBLESHOOTING...1343
      CHECKS AND ADJUSTMENTS FOR THE ENGINE...1345
        Engine Oil Pressure...1345
        Valve Clearance...1345
        Compression...1346
        Throttle And Governor Linkage...1346
        Ignition System...1347
        Spark Plugs...1347
      CARBURETOR & FUELSHUT–OFF SOLENOID...1348
        Removing The Carburetor...1348
        Disassembly And Inspection Of The Carburetor ...1348
        Assembly Of The Carburetor...1348
        Fuel Shut–off Solenoid...1349
        Non–Metallic Bodied Fuel Pumps...1349
      GOVERNOR...1349
        Removing The Governor...1349
        Installing The Governor...1349
      ENGINE AND HEAT SHIELD...1350
        Removing The Engine...1350
        Installing The Engine...1351
        Removing The Heat Shield...1352
        Installing The Heat Shield...1352
      RECONDITIONING THEVALVES...1353
        Repair Of The Valves And Guides...1353
      TIMING COVER, TIMING GEARS AND CAMSHAFT...1354
        Timing Cover...1354
        Timing Gears...1354
        Camshaft And Tappets...1354
      OIL PUMP AND RELIEF VALVE...1354
        Relief Valve...1354
        Oil Pump...1355
        Adjusting Gear Clearance For The Oil Pump...1355
      PISTONS, RODS AND CRANKSHAFT...1356
        Removing Pistons, Rods And Crankshaft...1356
        Crankshaft Bearing And End Play...1356
      CYLINDER HEAD...1357
      INTAKE AND EXHAUST MANIFOLD...1358
      FLYWHEEL...1358
    ENGINE SERVICE (543 & 543B) KUBOTA...1359
      TROUBLESHOOTING...1361
      FUEL SYSTEM...1363
        Replacing The Fuel Filter...1363
        To Remove The Air From The Fuel System...1363
        Fuel Injection Pump...1364
        Checking The Injection Pump...1364
        Installation...1367
        Timing The Fuel Injection Pump...1367
        Fuel Injector Nozzles...1368
        Removal...1368
        Checking The Fuel Injector Nozzles...1369
        Installation...1371
        Checking Glow Plugs...1371
      ENGINE AND ATTACHING PARTS...1371
        Removing The Engine...1371
        Installing The Engine...1375
        Engine Muffler...1376
        Engine Radiator Removal...1377
        Engine Radiator Installation...1379
        Engine Blower Housing Removal...1380
        Engine Blower Housing Installation...1381
        Engine Blower Fan And Flywheel Removal...1381
        Engine Blower Fan And Flywheel Installation...1381
      CYLINDER HEAD...1382
        Removing The Cylinder Head...1382
        Disassembly Of The Cylinder Head...1383
        Servicing The Cylinder Head...1383
         Assembly Of The Cylinder Head...1385
        Installing The Cylinder Head...1385
        Adjusting the Compression Release Mechanism...1386
      REPAIRING THE ENGINE...1387
        Removing The Gear Case...1387
        Removing The Timing Gear, Camshaft & Oil Pump...1388
        Removing Pistons And Crankshaft...1389
        Servicing The Timing Gear And The Camshaft...1390
        Servicing The Connecting Rods And Pistons...1391
        Servicing The Crankshaft...1392
        Servicing The Cylinder Liners...1393
        Servicing The Oil Pump...1394
        Servicing The Water Pump...1395
      ASSEMBLY OF THE ENGINE...1395
        Installing The Crankshaft...1395
        Installing The Pistons...1395
        Installing The Camshaft And Timing Gears...1396
        Installing The Gear Case Cover...1397
  TECHNICAL DATA...1399
    (540) KOHLER LOADER SPECIFICATIONS...1401
      Operation & Performance...1401
      Engine...1401
      Loader Hydraulics...1402
      Electrical...1402
      Drive System...1402
      Capacities...1402
      Tires...1402
    ENGINE SPECIFICATIONS – 540 LOADER (KOHLER)...1403
      Engine (General)...1403
      Cylinder Bore...1403
      Crankshaft...1403
      Camshaft...1403
      Connecting Rod...1403
      Piston, Pin And Rings...1403
      Valves, Guides & Tappets...1404
      Engine Torque...1404
    543 & 543B KUBOTA LOADER SPECIFICATIONS...1405
      Operation & Performance...1405
      Engine...1405
      Loader Hydraulics...1406
      Electrical...1406
      Drive System...1406
      Capacities...1406
      Tires ...1406
    ENGINE SPECIFICATIONS - 543-543B LOADER...1407
      Fuel Injector Nozzles...1407
      Fuel Injection Pump...1407
      Cylinder Head...1407
      Valves...1407
      Valve Springs...1407
      Rocker Arms...1407
      Camshaft...1407
      Cylinders...1408
      Piston Rings...1408
      Piston...1408
      Crankshaft...1408
      Oil Pump...1408
      Thermostat...1408
      Engine Torque...1409
      Grinding Specifications for the Crankshaft...1410
    TORQUE SPECIFICATIONS...1411
      Engine Group – 540 Loader...1411
      Engine Group – 543 Loader...1412
      Fuel System Group...1414
      Steering Levers & Panel Group...1415
      Bob–Tach & Lift Arm Group...1416
      Seat Bar & Pedal Group...1417
      Brake, Chaincase & Axle Group...1418
      Hydraulic Group...1419
      Operator Cab, Main Frame & Rear Door Group...1420
      Hydrostatic Group–540 Loader...1421
      Hydrostatic Group–543 Loader...1422
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...1423
      Hydraulic/Hydrostatic Fluid...1423
    DECIMAL AND MILLIMETER EQUIVALENTS...1424
    U.S. TO METRIC CONVERSION...1424
    STANDARD TORQUE SPECIFICATIONS FOR BOLTS...1425
  SERVICE MANUAL REVISIONS...1427
    540–3...1427
    540–4...1429
    540–5...1431
    540–6...1433
    540–7...1435
    540–8...1437
    540–9...1439
    540–11...1441
    540–13...1443
    540–14...1445
    540–15...1447
    540–16...1449
    540–17...1451
    540–1 Thru 540–17...1453
    540–18...1455
    540–19...1457
    540-20...1459
6566655 (5-84) - 540 Loader Operator& Manual...1461
  WARNINGS...1462
  FOREWORD...1463
    CONTENTS...1463
    REFERENCE INFORMATION...1463
    SAFETY INSTRUCTIONS...1465
      Safety Is Your Responsibility...1465
      Before You Operate The Bobcat Loader...1465
      Safe Operation Needs A Qualified Operator...1466
    FIRE PREVENTION...1466
    SERIAL NUMBER LOCATIONS...1467
      Loader Serial Number...1467
      Engine Serial Number...1467
    DELIVERY REPORT...1467
    BOBCAT LOADER IDENTIFICATION...1468
  OPERATING INSTRUCTIONS...1469
    OPERATING INSTRUCTIONS...1471
    MACHINE SIGNS (DECALS)...1472
    CONTROLS...1472
    DASH PANEL...1475
    THROTTLE CONTROL...1475
    CHOKE CONTROL...1475
    PARKING BRAKE...1475
    STOPPING THE ENGINE...1476
    STEERING LEVERS...1476
    HYDRAULIC CONTROLS...1477
      Foot Pedals (Hydraulic)...1477
      Lift Arm Operation...1477
      Float Position...1477
      Tilt (Bucket) Operation...1477
      Auxiliary Lever Operation...1478
    BEFORE YOU START THE ENGINE...1479
    STARTING THE ENGINE...1480
      Normal Starting Condition...1481
      Cold Temperature Starting Condition...1481
    ATTACHMENTS & BUCKETS...1482
      Installation of Attachments...1483
      Removal Of Attachments...1483
    OPERATING PROCEDURE...1484
      Filling The Bucket...1484
      To Empty The Bucket...1485
      Digging Into The Ground...1486
      MakingThe Ground Level Using Float Position...1486
      Filling A Hole...1486
    LIFTING THE BOBCAT LOADER...1487
    PARKING THE BOBCAT LOADER...1487
    TRANSPORTING THE BOBCAT LOADER...1487
    LIFT ARM STOP...1488
    LIFTING THE OPERATOR CAB...1488
    LOWERING THE OPERATOR CAB...1489
    LIFTING THE BOBCAT LOADER...1490
  PREVENTIVE MAINTENANCE...1491
    WARNINGS...1492
    SERVICE SCHEDULE...1493
    ENGINE SERVICE...1494
    ADJUSTING THE DOOR LATCH...1494
    AIR CLEANER SERVICE...1494
    FUEL SYSTEM...1495
    FUEL SYSTEM SERVICE...1495
    FUEL FILTER...1495
    ENGINE LIBRICATION SYSTEM...1496
    REPLACEMENT OF THE ENGINE OIL & FILTER...1496
    ENGINE COOLING SYSTEM...1497
    ELECTRICAL SYSTEM...1497
    USING AN EXTRA BATTERY (JUMP STARTING)...1500
    INSTALLING A NEW BATTERY...1501
    SPARK ARRESTOR MUFFLER...1502
    HYDRAULIC / HYDROSTATIC SYSTEM...1502
    REPLACEMENT OF THE HYDRAULIC FILTER ELEMENT...1504
    HYDRAULIC / HYDROSTATIC FLUID RESERVOIR...1504
      Checking And Adding Fluid...1504
      Hydraulic / Hydrosttatic Fluid Reservoir Breather Cap...1505
      Removing The Hydraulic / Hydrostatic Fluid...1505
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1505
      Checking The Chaincase Fluid Level...1505
    TIRE MAINTENANCE...1506
      Tire Rotation...1506
      Wheel Nuts...1506
    LUBRICATION OF THE BOBCAT LOADER...1506
    OPERATOR CAB (ROPS & FOPS)...1507
    BOB-TACH...1507
    PIVOT PINS...1508
    BRAKE PEDAL ADJUSTMENT...1508
  TROUBLESHOOTING...1509
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...1511
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM...1512
    TROUBLESHOOTING THE ENGINE...1513
  MAJOR PARTS...1515
    MAIN FRAME...1517
    PANELS, SEAT, SEAT BAR & FUEL SYSTEM...1518
    BRAKE, CHAINCASE & AXLE...1519
    HYDRAULIC SYSTEM...1520
    HYDROSTATIC SYSTEM...1521
    STEERING CONTROLS...1522
    OPERATOR CAB ELECTRICAL SYSTEM...1523
    LIFT ARMS, BOB-TACH & CONTROL PEDALS...1524
    ENGINE ELECTRICAL SYSTEM...1525
    ENGINE & ATTACHING PARTS...1526
  WARNING SIGNS...1527
    WARNING - 6565980...1529
    SERVICE SCHEDULE - 6565318...1530
    WARNING - 6563380...1532
    WARNING - 6561380...1533
    IMPORTANT - 6560573...1534
  GENERAL INFORMATION...1535
    540 LOADER SPECIFICATIONS...1537
      Operation & Performance...1537
      Engine...1537
      Loader Hydraulics...1538
      Electrical...1538
      Drive System...1538
      Capacities...1538
      Tires...1538
    ADDITIONAL PUBLICATIONS...1539
  WARRANTY...1541
6566656 (9-83) - 543 Loader Operator& Manual...1543
  WARNINGS...1545
  FOREWORD...1547
    CONTENTS...1547
    REFERENCE INFORMATION...1547
    SAFETY INSTRUCTIONS...1549
      Safety Is The Operator& Responsibility...1549
      Before You Operate The Bobcat Loader...1549
      Safe Operation Needs A Qualified Operator...1550
    FIRE PREVENTION...1550
    SERIAL NUMBER IDENTIFICATION...1551
      Loader Serial Number...1551
      Engine Serial Number Location...1551
  DELIVERY REPORT...1551
  OPERATING INSTRUCTIONS...1553
    OPERATING INSTRUCTIONS...1555
    MACHINE SIGNS (DECALS)...1556
    CONTROLS...1556
    DASH PANEL...1559
    THROTTLE CONTROL...1559
    STOPPING THE ENGINE...1559
    PARKING BRAKE...1559
    STEERING LEVERS...1560
    HYDRAULIC CONTROLS...1561
      Foot Pedals (Hydraulic)...1561
      Lift Arm Operation...1561
      Float Position...1561
      Tilt (Bucket) Operation...1561
      Auxiliary Lever Operation...1562
    BEFORE YOU START THE ENGINE...1563
    STARTING THE ENGINE...1564
      Normal Starting Condition...1565
      Cold Temperature Starting Condition...1565
    ATTACHMENTS & BUCKETS...1566
      Installation Of Attachments...1567
      Removal Of Attachments...1568
    OPERATING PROCEDURE...1568
      Filling The Bucket...1569
      To Empty The Bucket...1569
      Digging Into The Ground...1570
      Making The Ground Level Using Float Position...1570
      Fill A Hole...1570
    LIFTING THE BOBCAT LOADER...1571
    PARKING THE BOBCAT LOADER...1571
    TRANSPORTING THE BOBCAT LOADER...1571
    LIFT ARM STOP...1572
    LIFTING THE OPERATOR CAB...1572
    LOWERING THE OPERATOR CAB...1573
    LIFTING THE BOBCAT LOADER...1574
  PREVENTIVE MAINTENANCE...1575
    WARNINGS...1576
    SERVICE SCHEDULE...1577
    ENGINE SERVICE...1578
    ADJUSTING THE DOOR LATCH...1578
    AIR CLEANER SERVICE...1578
    FUEL SYSTEM...1579
    FUEL SYSTEM SERVICE...1579
    FUEL FILTER...1579
    REMOVING WATER FROM THE FUEL SYSTEM...1580
    REMOVING AIR FROM THE FUEL SYSTEM...1580
    ENGINE LUBRICATION SYSTEM...1580
    REPLACEMENT OF ENGINE OIL AND FILTER...1581
    COOLANT LEVEL...1582
    REMOVING THE COOLANT FROM THE COOLING SYSTEM...1582
    ALTERNATOR BELT...1582
    ELECTRICAL SYSTEM...1585
    USING AN EXTRA BATTERY (JUMP STARTING)...1585
    INSTALLING A NEW BATTERY...1586
    SPARK ARRESTOR MUFFLER...1587
    HYDRAULIC / HYDROSTATIC SYSTEM...1587
    REPLACEMENT OF THE HYDRAULIC FILTER ELEMENT...1589
    HYDRAULIC / HYDROSTATIC FLUID RESERVOIR...1589
      Checking And Adding Fluid...1589
      Hydraulic / Hydrostatic Fluid Reservoir Breather Cap...1590
      Removing The Hydraulic / Hydrostaic Fluid...1590
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1590
    TIRE MAINTENANCE...1590
      Tire Rotation...1591
      Wheel Nuts...1591
    LUBRICATION OF THE BOBCAT LOADER...1591
    ROLL OVER PROTECTIVE STRUCTURE (ROPS & FOPS)...1592
    BOB-TACH...1592
    PIVOT PINS...1593
    BRAKE PEDAL ADJUSTMENT...1593
  TROUBLESHOOTING...1595
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...1597
    TROUBLESHOOTING THE ENGINE...1599
  MAJOR PARTS...1601
    MAIN FRAME...1603
    PANELS, SEAT, SEAT BAR & FUEL SYSTEM...1604
    BRAKES, CHAINCASE & AXLE...1605
    HYDRAULIC SYSTEM...1606
    HYDROSTATIC SYSTEM...1607
    STEERING CONTROLS...1608
    OPERATOR CAB ELECTRICAL SYSTEM...1609
    LIFT ARMS, BOB-TACH & CONTROL PEDALS...1610
    ENGINE ELECTRICAL SYSTEM...1611
    ENGINE & ATTACHING PARTS...1612
  WARNING SIGNS...1615
    WARNING - 6565980...1617
    SERVICE SCHEDULE - 6565318...1618
    WARNING - 6563380...1620
    WARNING - 6561380...1621
    IMPORTANT - 6560573...1622
  GENERAL INFORMATION...1623
    LOADER SPECIFICATIONS...1625
      Operation & Performance...1625
      Engine...1625
      Loader Hydraulics...1626
      Electrical...1626
      Drive System...1626
      Capacitities...1626
      Tires...1626
    ADDITIONAL PUBLICATIONS...1627
  WARRANTY...1629
6566858 (8-84) - 540 Loader Operator& Manual...1631
  OPERATOR SAFETY WARNINGS...1632
  FOREWORD...1633
    CONTENTS...1633
    REFERENCE INFORMATION...1633
    SAFETY INSTRUCTIONS...1635
      Safety Is Your Responsibility...1635
      Before Operating The Bobcat Loader...1635
      Safe Operation Needs A Qualified Operator...1636
    FIRE PREVENTION...1636
    SERIAL NUMBER LOCATIONS...1637
      Loader Serial Number...1637
      Engine Serial Number...1637
    DELIVERY REPORT...1637
    BOBCAT LOADER IDENTIFICATION...1638
  OPERATING INSTRUCTIONS...1639
    OPERATING INSTRUCTIONS...1641
    GETTING ON AND OFF THE LOADER...1641
    SAFETY SIGNS (DECALS)...1642
    LEARNING THE CONTROLS...1642
    DASH PANEL...1645
    THROTTLE CONTROL...1645
    CHOKE CONTROL...1645
    PARKING BRAKE...1645
    STEERING LEVERS...1646
    HYDRAULIC CONTROLS...1647
      Left Foot Pedal / Lift Arm Operation...1647
      Left Foot Pedal / Float Postion For The Lift Arms...1647
      Right Foot Pedal / Tilt (Bucket) Operation...1647
      Right Lever / Auxiliary Operation...1648
    BEFORE STARTING THE ENGINE...1648
    STARTING THE ENGINE...1650
      Cold Temperature Starting...1651
    ATTACHMENTS AND BUCKETS...1652
      Bucket Or Fork Installation...1653
      Bucket Or Fork Removal...1653
    OPERATING PROCEDURES...1654
      Filling The Bucket...1655
      Emptying The Bucket...1655
      Digging Into The Ground...1656
      Leveling The Ground (Using Float Position For The Lift Arms)...1656
      Backfilling...1657
    PARKING THE LOADER...1657
    TOWING THE LOADER...1657
    TRANSPORTING THE LOADER...1657
    LIFTING THE LOADER...1658
  PREVENTIVE MAINTENANCE...1659
    MAINTENANCE SAFETY WARNINGS...1660
    SERVICE SCHEDULE...1661
    LIFT ARM STOP...1662
    OPERATOR CAB...1662
      Raising The Operator Cab...1663
      Lowering The Operator Cab...1663
    REAR DOOR...1663
      Door Latch Adjustment...1664
    AIR CLEANER...1664
    FUEL SYSTEM...1665
      Filling The Fuel Tank...1665
      Fuel Filter...1666
    ENGINE LUBRICATION SYSTEM...1667
      Engine Oil And Filter Replacement...1667
    COOLING SYSTEM...1669
    ELECTRICAL SYSTEM...1672
      Electrical System Service...1672
      Using An Extra Battry (Jump Starting)...1672
      Battery Replacement...1674
    HYDRAULIC / HYDROSTATIC SYSTEM...1674
      Hydraulic / Hydrostatic Fluid Reservoir...1674
      Checking And Adding Fluid...1674
      Hydraulic Fluid Replacement...1676
      Hydraulic Filter Replacement...1676
    SPARK ARRESTOR MUFFLER...1677
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1677
      Chaincase Fluid Level...1677
    TIRE MAINTENANCE...1678
      Tire Rotation...1678
      Wheel Nuts...1678
    LOADER LUBRICATION...1679
    BOB-TACH...1680
    PIVOT PINS...1680
    BRAKE PEDAL ADJUSTMENT...1680
  TROUBLESHOOTING...1681
    TROUBLESHOOTING THE ENGINE...1683
    TROUBLESHOOTING THE DRIVE SYSTEM...1684
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...1685
  MAJOR PARTS...1687
    MAIN FRAME...1689
    PANELS, SEAT, SEAT BAR & FUEL SYSTEM...1690
    DRIVE SYSTEM...1691
    HYDRAULIC SYSTEM...1692
    HYDROSTATIC SYSTEM...1693
    HAND CONTROLS AND CONTROL PEDALS...1694
    OPERATOR CAB ELECTRICAL SYSTEM...1695
    ENGINE ELECTRICAL SYSTEM...1696
    ENGINE & ATTACHING PARTS...1697
  SAFETY SIGNS...1699
    WARNING - 6565980...1701
    SERVICE SCHEDULE - 6567875...1702
    WARNING - 6568692...1704
    WARNING - 6568691...1705
    IMPORTANT - 6560573...1706
  SPECIFICATIONS...1707
    LOADER SPECIFICATIONS...1709
      Operation & Performance...1709
      Engine...1709
      Hydraulic System...1710
      Electrical...1710
      Drive System...1710
      Capacities...1710
      Tires...1710
    ADDITIONAL PUBLICATIONS...1711
  WARRANTY...1713
6570791 (5-88) - 542B Loader Service Manual...1715
  MAINTENANCE SAFETY...1717
  CONTENTS...1719
    FOREWORD...1721
    SERIAL NUMBER LOCATIONS...1723
      Loader Serial Number...1723
      Engine Serial Number...1723
    DELIVERY REPORT...1723
    BOBCAT LOADER IDENTIFICATION...1724
  PREVENTIVE MAINTENANCE...1725
    SERVICE SCHEDULE...1727
    PREVENTIVE MAINTENANCE...1728
    LIFTING AND BLOCKING THE LOADER...1728
      Procedure...1728
    LIFT ARM STOP...1729
      Procedure...1729
    TRANSPORTING THE BOBCAT LOADER...1729
      Procedure...1729
    OPERATOR CAB...1730
      Operator Cab Fasteners...1730
      Raising And Lowering The Operator Cab...1730
    SEAT BAR SYSTEM...1731
      Seat Bar Description...1731
      Seat Bar Inspection...1731
      Seat Bar Maintenance...1731
    USING AN EXTRA BATTERY (JUMP STARTING)...1732
      Procedure...1732
    AIR CLEANER...1733
      Replacement Of Filter Element...1733
    FUEL SYSTEM...1734
      Filling The Fuel Tank...1734
      Fuel Filter...1734
    ENGINE LUBRICATION SYSTEM...1735
      Checking Engine Oil...1735
      Replacement Of Engine Oil And Filter...1735
    COOLING SYSTEM...1736
      Rear Grill...1736
      Coolant Level...1737
      Removing Coolant From The Cooling System...1737
    HYDRAULIC / HYDROSTATIC SYSTEM...1738
      Checking And Adding Fluid...1738
      Replacement Of The Hydraulic Filter Element...1738
      Removing The Hydraulic Fluid...1739
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1740
      Checking Oil Level...1740
    TIRE MAINTENANCE...1740
      Wheel Nuts...1740
      Tire Rotation...1740
      Tire Inflation...1740
    LUBRICATION OF THE LOADER...1741
      Procedure...1741
    REMOTE START SWITCH...1742
      Procedure...1742
  HYDRAULIC SYSTEM...1743
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1745
    TROUBLESHOOTING...1751
    HYDRAULIC SYSTEM INFORMATION...1752
      Flare Connections...1752
      Straight Thread O-Ring Fitting...1752
      Tubelines And Hoses...1752
    LIFT CYLINDER...1753
      Checking The Lift Cylinder(s)...1753
      Removal And Installation...1753
    TILT CYLINDER...1755
      Checking The Tilt Cylinder...1755
      Removal And Installation...1755
      Rod End Seal...1756
    HYDRAULIC CONTROL VALVE...1757
      Checking The Main Relief Valve With Auxiliary Couplers (Opt.)...1757
      Checking The Main Relief Valve Without Auxiliary Hydraulics...1758
      Main Relief Valve Removal And Installation...1759
      Adjusting The Main Relief Valve...1759
      Removal And Installation...1760
    HYDRAULIC PUMP...1762
      Checking The Output Of The Hydraulic Pump...1762
      Removal And Installation...1763
    PORT BLOCK...1764
      Removal And Installation...1764
      Charge By-Pass Valve...1764
    FILTER BY-PASS VALVE...1766
      Removal And Installation...1766
    HYDRAULIC FLUID RESERVOIR...1767
      Removal And Installation...1767
    HYDRAULIC CONTROL PEDALS...1768
      Removal And Installation...1768
      Adjustment...1768
    PEDAL LOCK LINKAGE...1769
      Installation...1769
      Adjustment...1769
  HYDROSTATIC SYSTEM...1771
    TROUBLESHOOTING...1773
    HYDROSTATIC SYSTEM INFORMATION...1774
      High Pressure Relief/Rreplenishing Valve Function...1774
    FRONT PANEL...1775
      Removal And Installation...1775
    STEERING LEVERS...1777
      Removal And Installation...1777
      Repairing The Steering Levers...1778
    STEERING LINKAGE...1779
      Steering Linkage Adjustment...1779
      Removal And Installation...1780
      Repairing The Pintle Lever...1781
    HYDROSTATIC MOTOR...1783
      Removal And Installation...1783
      Start-Up Procedure...1784
    HYDROSTATIC PUMP...1785
      Checking The Charge Pressure...1785
      Checking High Pressure Relief/Replenishing Valves...1786
      Removal And Installation...1787
      High Pressure Hose Routing...1789
      Start-Up Procedure...1789
    TOWING THE LOADER...1790
      Procedure...1790
  DRIVE SYSTEM...1791
    PARKING BRAKE...1793
      Adjustment...1793
      Removal And Installation...1793
      Block And Pucks...1794
    AXLES, SEALS AND BEARINGS...1796
      Removal...1796
      Installation...1797
    FINAL DRIVE CHAIN...1800
      Removal...1800
      Installation...1800
    CHAINCASE FLUID...1801
      Replacing The Chaincase Fluid...1801
  MAIN FRAME...1803
    OPERATOR CAB...1805
      Removal And Installation...1805
    OPERATOR CAB GAS CYLINDER...1808
      Removal And Installation...1808
    REAR DOOR...1809
      Door Latch Adjustment...1809
      Removal And Installation...1810
    LIFT ARMS...1811
      Removal And Installation...1811
    BOB-TACH...1813
      Removal And Installation...1813
      Tilt Cylinder Rod End Seal...1814
      Bob-Tach Wedges...1815
    FUEL TANK...1817
      Removal And Installation...1817
  ELECTRICAL SYSTEM...1819
    ELECTRICAL SCHEMATICS...1822
    ELECTRICAL SYSTEM INFORMATION...1833
      Description...1833
    TROUBLESHOOTING...1833
    BATTERY...1834
      Checking The Battery...1834
      Removal And Installation...1834
    ALTERNATOR...1835
      Checking The Alternator Output...1835
      Checking The Alternator Regulator...1835
      Removal And Installation...1836
      Disassenbly And Assembly...1837
      Checking Rotor, Stator And Rectifier...1837
    STARTER...1840
      Checking The Starter...1840
      Removal And Installation...1840
      Disassembly And Assembly...1841
      Cleaning And Inspection...1842
      Replacing The Brushes...1842
  ENGINE SERVICE...1843
    TROUBLESHOOTING...1845
    VALVE CLEARANCE...1846
      Adjustment...1846
    BELT SHIELD...1847
      Removal And Installation...1847
    FUEL LIFT PUMP...1849
      Checking...1849
      Removal And Installation...1849
    CARBURETOR...1850
      Description...1850
      Operation...1850
      Removal And Installation...1852
      Disassembly And Assembly...1854
      Inspection...1854
    IGNITION SYSTEM...1855
      Description...1855
      Troubleshooting...1856
      Ignition Timing Procedure...1857
    DISTRIBUTOR...1858
      Removal And Installation...1858
      Disassembly And Assembly...1859
      Checking The Distibutor...1859
      Spark Advance Test...1859
    IGNITION - DISTRIBUTORLESS...1860
      Description...1860
      Engine, Speed, Load & Temperature...1860
      Service Adjustments And Checks...1861
      Coil Removal And Installation...1861
      Engine Speed Sensor...1862
      Engine Coolant Temperature Sensor...1862
    GOVENOR...1864
      Belt Adjustment...1864
      Govenor Oil Level...1864
      Removal And Installation...1864
      Adjusting The Govenor...1865
    ENGINE MUFFLER...1867
      Removal And Installation...1867
    RADIATOR...1869
      Removal And Installation...1869
    ENGINE...1871
      Removal And Installation...1871
    OIL COOLER AND BLOWER HOUSING...1874
      Removal And Installation...1874
    FLYWHEEL AND U-JOINT...1877
      Removal And Installation...1877
      Flywheel Ring Gear...1878
    ROCKER ARMS...1879
      Removal And Installation...1879
      Disassembly And Assembly...1879
      Inspection...1879
    CYLINDER HEAD...1879
      Removal And Installation...1879
      Cleaning...1880
      Inspection...1880
    VALVES, VALVE GUIDES & SPRINGS...1881
      Removal...1881
      Valve Guides...1881
      Reconditioning The Valve And Valve Seat...1882
      Valve Springs...1882
    PISTON AND CONNECTING ROD...1883
      Removal And Installation...1883
      Fitting Pistons...1883
      Piston Rings...1884
      Piston Pin...1884
      Connecting Rods...1884
    CYLINDER BLOCK...1885
      Cleaning...1885
      Inspection...1885
      Refinishing Cylinder Bores...1885
    CRANKSHAFT FRONT OIL SEAL...1885
      Removal...1885
      Installation...1885
    CRANKSHAFT REAR OIL SEAL...1886
      Removal...1886
      Installation...1886
    CRANKSHAFT AND MAIN BEARINGS...1886
      Inspection...1886
      Refinishing Crankshaft Journals...1887
      Fitting Bearing with Plastigage...1887
      Crankshaft End Play...1888
    TIMING CHAIN COVER...1888
      Removal And Installation...1888
    TIMING CHAIN AND SPROCKETS...1888
      Removal...1888
      Inspection...1888
      Installation...1889
    CAMSHAFT...1889
      Checking Camshaft Lobe Lift...1889
      Removal And Installation...1890
      Inspection...1890
      Camshaft Bearing...1890
      Camshaft End Play...1890
    PUCH RODS AND TAPPETS...1891
      Inspecting The Push Rods...1891
      Inspecting The Tappet...1891
    OIL PAN...1891
      Removal...1891
      Cleaning And Inspection...1891
      Installation...1891
    OIL PUMP...1892
      Disassembly...1892
      Inspection...1892
      Assembly...1892
  TECHNICAL DATA...1893
    LOADER/ENGINE SPECIFICATIONS (S/N 11999 & BELOW)...1895
      SPECIFICATIONS...1897
        OPERATION AND PERFORMANCE...1897
        ENGINE...1897
        ELECTRICAL...1898
        DRIVE SYSTEM...1898
        HYDRAULIC SYSTEM...1898
        CAPACITIES...1898
        TIRES...1898
      ENGINE SPECIFICATIONS (S/N 11999 & BELOW)...1899
        Cylinder Block...1899
        Crankshaft...1899
        Connecting Rod...1899
        Pistons...1899
        Piston Pins...1899
        Piston Rings...1899
        Cylinder Head...1900
        Valves...1900
        Valve Springs...1900
        Tappets...1900
        Rocker Arms & Shaft...1900
        Oil Pump...1900
        Camshaft...1901
        Ignition System - Solid State...1901
        Distributor Advance...1901
        Belt Tension...1901
        Fuel Pump...1901
        Engine Torque...1902
      LOADER TORQUES...1903
      HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...1904
      DECIMAL AND MILLIMETER EQUIVALENTS...1905
      U.S. TO METRIC CONVERSION...1905
      STANDARD TORQUE SPECIFICATIONS FOR BOLTS...1906
    LOADER/ENGINE SPECIFICATIONS (S/N 12001 & ABOVE)...1907
      SPECIFICATIONS...1909
        OPERATION AND PERFORMANCE...1909
        ENGINE...1909
        HYDRAULIC SYSTEM...1910
        ELECTRICAL...1910
        DRIVE SYSTEM...1910
        CAPACITIES...1910
        TIRES...1910
      ENGINE SPECIFICATIONS...1911
        Cylinder Block...1911
        Crankshaft...1911
        Connecting Rod...1911
        Pistons...1911
        Piston Pins...1911
        Piston Rings...1911
        Cylinder Head...1912
        Valves...1912
        Valve Springs...1912
        Tappets...1912
        Rocker Arms & Shaft...1912
        Oil Pump...1912
        Camshaft...1913
        Ignition System - Distributorless...1913
        Belt Tension...1913
        Fuel Pump...1913
        Engine Torque...1914
  SERVICE MANUAL REVISIONS...1915
    542B-1...1915
    542B-2...1917
    542B-3...1919
    542B-4...1921
    542B-5...1923
    542B-6...1925
    542B-7...1927
6570791 (6-12) - 542B Loader Service Manual...1929
  MAINTENANCE SAFETY...1931
  CONTENTS...1933
    FOREWORD...1935
    SERIAL NUMBER LOCATIONS...1937
      Loader Serial Number...1937
      Engine Serial Number...1937
    DELIVERY REPORT...1937
    BOBCAT LOADER IDENTIFICATION...1938
  PREVENTIVE MAINTENANCE...1939
    SERVICE SCHEDULE...1941
    PREVENTIVE MAINTENANCE...1942
    LIFTING AND BLOCKING THE LOADER...1942
      Procedure...1942
    LIFT ARM STOP...1943
      Procedure...1943
    TRANSPORTING THE BOBCAT LOADER...1943
      Procedure...1943
    OPERATOR CAB...1944
      Operator Cab Fasteners...1944
      Raising And Lowering The Operator Cab...1944
    SEAT BAR SYSTEM...1945
      Seat Bar Description...1945
      Seat Bar Inspection...1945
      Seat Bar Maintenance...1945
    USING AN EXTRA BATTERY (JUMP STARTING)...1946
      Procedure...1946
    AIR CLEANER...1947
      Replacement Of Filter Element...1947
    FUEL SYSTEM...1948
      Filling The Fuel Tank...1948
      Fuel Filter...1948
    ENGINE LUBRICATION SYSTEM...1949
      Checking Engine Oil...1949
      Replacement Of Engine Oil And Filter...1949
    COOLING SYSTEM...1950
      Rear Grill...1950
      Coolant Level...1951
      Removing Coolant From The Cooling System...1951
    HYDRAULIC / HYDROSTATIC SYSTEM...1952
      Checking And Adding Fluid...1952
      Replacement Of The Hydraulic Filter Element...1952
      Removing The Hydraulic Fluid...1953
    FINAL DRIVE TRANSMISSION (CHAINCASE)...1954
      Checking Oil Level...1954
    TIRE MAINTENANCE...1954
      Wheel Nuts...1954
      Tire Rotation...1954
      Tire Inflation...1954
    LUBRICATION OF THE LOADER...1955
      Procedure...1955
    REMOTE START SWITCH...1956
      Procedure...1956
  HYDRAULIC SYSTEM...1957
    HYDRAULIC / HYDROSTATIC SCHEMATICS...1959
    TROUBLESHOOTING...1965
    HYDRAULIC SYSTEM INFORMATION...1966
      Flare Connections...1966
      Straight Thread O-Ring Fitting...1966
      Tubelines And Hoses...1966
    LIFT CYLINDER...1967
      Checking The Lift Cylinder(s)...1967
      Removal And Installation...1967
    TILT CYLINDER...1969
      Checking The Tilt Cylinder...1969
      Removal And Installation...1969
      Rod End Seal...1970
    HYDRAULIC CONTROL VALVE...1971
      Checking The Main Relief Valve With Auxiliary Couplers (Opt.)...1971
      Checking The Main Relief Valve Without Auxiliary Hydraulics...1972
      Main Relief Valve Removal And Installation...1973
      Adjusting The Main Relief Valve...1973
      Removal And Installation...1974
    HYDRAULIC PUMP...1976
      Checking The Output Of The Hydraulic Pump...1976
      Removal And Installation...1977
    PORT BLOCK...1978
      Removal And Installation...1978
      Charge By-Pass Valve...1978
    FILTER BY-PASS VALVE...1980
      Removal And Installation...1980
    HYDRAULIC FLUID RESERVOIR...1981
      Removal And Installation...1981
    HYDRAULIC CONTROL PEDALS...1982
      Removal And Installation...1982
      Adjustment...1982
    PEDAL LOCK LINKAGE...1983
      Installation...1983
      Adjustment...1983
  HYDROSTATIC SYSTEM...1985
    TROUBLESHOOTING...1987
    HYDROSTATIC SYSTEM INFORMATION...1988
      High Pressure Relief/Rreplenishing Valve Function...1988
    FRONT PANEL...1989
      Removal And Installation...1989
    STEERING LEVERS...1991
      Removal And Installation...1991
      Repairing The Steering Levers...1992
    STEERING LINKAGE...1993
      Steering Linkage Adjustment...1993
      Removal And Installation...1994
      Repairing The Pintle Lever...1995
    HYDROSTATIC MOTOR...1997
      Removal And Installation...1997
      Start-Up Procedure...1998
    HYDROSTATIC PUMP...1999
      Checking The Charge Pressure...1999
      Checking High Pressure Relief/Replenishing Valves...2000
      Removal And Installation...2001
      High Pressure Hose Routing...2003
      Start-Up Procedure...2003
    TOWING THE LOADER...2004
      Procedure...2004
  DRIVE SYSTEM...2005
    PARKING BRAKE...2007
      Adjustment...2007
      Removal And Installation...2007
      Block And Pucks...2008
    AXLES, SEALS AND BEARINGS...2010
      Removal...2010
      Installation...2011
    FINAL DRIVE CHAIN...2014
      Removal...2014
      Installation...2014
    CHAINCASE FLUID...2015
      Replacing The Chaincase Fluid...2015
  MAIN FRAME...2017
    OPERATOR CAB...2019
      Removal And Installation...2019
    OPERATOR CAB GAS CYLINDER...2022
      Removal And Installation...2022
    REAR DOOR...2023
      Door Latch Adjustment...2023
      Removal And Installation...2024
    LIFT ARMS...2025
      Removal And Installation...2025
    BOB-TACH...2027
      Removal And Installation...2027
      Tilt Cylinder Rod End Seal...2028
      Bob-Tach Wedges...2029
    FUEL TANK...2031
      Removal And Installation...2031
  ELECTRICAL SYSTEM...2033
    ELECTRICAL SCHEMATICS...2036
    ELECTRICAL SYSTEM INFORMATION...2047
      Description...2047
    TROUBLESHOOTING...2047
    BATTERY...2048
      Checking The Battery...2048
      Removal And Installation...2048
    ALTERNATOR...2049
      Checking The Alternator Output...2049
      Checking The Alternator Regulator...2049
      Removal And Installation...2050
      Disassenbly And Assembly...2051
      Checking Rotor, Stator And Rectifier...2051
    STARTER...2054
      Checking The Starter...2054
      Removal And Installation...2054
      Disassembly And Assembly...2055
      Cleaning And Inspection...2056
      Replacing The Brushes...2056
  ENGINE SERVICE...2057
    TROUBLESHOOTING...2059
    VALVE CLEARANCE...2060
      Adjustment...2060
    BELT SHIELD...2061
      Removal And Installation...2061
    FUEL LIFT PUMP...2063
      Checking...2063
      Removal And Installation...2063
    CARBURETOR...2064
      Description...2064
      Operation...2064
      Removal And Installation...2066
      Disassembly And Assembly...2068
      Inspection...2068
    IGNITION SYSTEM...2069
      Description...2069
      Troubleshooting...2070
      Ignition Timing Procedure...2071
    DISTRIBUTOR...2072
      Removal And Installation...2072
      Disassembly And Assembly...2073
      Checking The Distibutor...2073
      Spark Advance Test...2073
    IGNITION - DISTRIBUTORLESS...2074
      Description...2074
      Engine, Speed, Load & Temperature...2074
      Service Adjustments And Checks...2075
      Coil Removal And Installation...2075
      Engine Speed Sensor...2076
      Engine Coolant Temperature Sensor...2076
    GOVENOR...2078
      Belt Adjustment...2078
      Govenor Oil Level...2078
      Removal And Installation...2078
      Adjusting The Govenor...2079
    ENGINE MUFFLER...2081
      Removal And Installation...2081
    RADIATOR...2083
      Removal And Installation...2083
    ENGINE...2085
      Removal And Installation...2085
    OIL COOLER AND BLOWER HOUSING...2088
      Removal And Installation...2088
    FLYWHEEL AND U-JOINT...2091
      Removal And Installation...2091
      Flywheel Ring Gear...2092
    ROCKER ARMS...2093
      Removal And Installation...2093
      Disassembly And Assembly...2093
      Inspection...2093
    CYLINDER HEAD...2093
      Removal And Installation...2093
      Cleaning...2094
      Inspection...2094
    VALVES, VALVE GUIDES & SPRINGS...2095
      Removal...2095
      Valve Guides...2095
      Reconditioning The Valve And Valve Seat...2096
      Valve Springs...2096
    PISTON AND CONNECTING ROD...2097
      Removal And Installation...2097
      Fitting Pistons...2097
      Piston Rings...2098
      Piston Pin...2098
      Connecting Rods...2098
    CYLINDER BLOCK...2099
      Cleaning...2099
      Inspection...2099
      Refinishing Cylinder Bores...2099
    CRANKSHAFT FRONT OIL SEAL...2099
      Removal...2099
      Installation...2099
    CRANKSHAFT REAR OIL SEAL...2100
      Removal...2100
      Installation...2100
    CRANKSHAFT AND MAIN BEARINGS...2100
      Inspection...2100
      Refinishing Crankshaft Journals...2101
      Fitting Bearing with Plastigage...2101
      Crankshaft End Play...2102
    TIMING CHAIN COVER...2102
      Removal And Installation...2102
    TIMING CHAIN AND SPROCKETS...2102
      Removal...2102
      Inspection...2102
      Installation...2103
    CAMSHAFT...2103
      Checking Camshaft Lobe Lift...2103
      Removal And Installation...2104
      Inspection...2104
      Camshaft Bearing...2104
      Camshaft End Play...2104
    PUCH RODS AND TAPPETS...2105
      Inspecting The Push Rods...2105
      Inspecting The Tappet...2105
    OIL PAN...2105
      Removal...2105
      Cleaning And Inspection...2105
      Installation...2105
    OIL PUMP...2106
      Disassembly...2106
      Inspection...2106
      Assembly...2106
  TECHNICAL DATA...2107
    LOADER/ENGINE SPECIFICATIONS (S/N 11999 & BELOW)...2109
      SPECIFICATIONS...2111
        OPERATION AND PERFORMANCE...2111
        ENGINE...2111
        ELECTRICAL...2112
        DRIVE SYSTEM...2112
        HYDRAULIC SYSTEM...2112
        CAPACITIES...2112
        TIRES...2112
      ENGINE SPECIFICATIONS (S/N 11999 & BELOW)...2113
        Cylinder Block...2113
        Crankshaft...2113
        Connecting Rod...2113
        Pistons...2113
        Piston Pins...2113
        Piston Rings...2113
        Cylinder Head...2114
        Valves...2114
        Valve Springs...2114
        Tappets...2114
        Rocker Arms & Shaft...2114
        Oil Pump...2114
        Camshaft...2115
        Ignition System - Solid State...2115
        Distributor Advance...2115
        Belt Tension...2115
        Fuel Pump...2115
        Engine Torque...2116
      LOADER TORQUES...2117
      HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...2118
      DECIMAL AND MILLIMETER EQUIVALENTS...2119
      U.S. TO METRIC CONVERSION...2119
      STANDARD TORQUE SPECIFICATIONS FOR BOLTS...2120
    LOADER/ENGINE SPECIFICATIONS (S/N 12001 & ABOVE)...2121
      SPECIFICATIONS...2123
        OPERATION AND PERFORMANCE...2123
        ENGINE...2123
        HYDRAULIC SYSTEM...2124
        ELECTRICAL...2124
        DRIVE SYSTEM...2124
        CAPACITIES...2124
        TIRES...2124
      ENGINE SPECIFICATIONS...2125
        Cylinder Block...2125
        Crankshaft...2125
        Connecting Rod...2125
        Pistons...2125
        Piston Pins...2125
        Piston Rings...2125
        Cylinder Head...2126
        Valves...2126
        Valve Springs...2126
        Tappets...2126
        Rocker Arms & Shaft...2126
        Oil Pump...2126
        Camshaft...2127
        Ignition System - Distributorless...2127
        Belt Tension...2127
        Fuel Pump...2127
        Engine Torque...2128
  SERVICE MANUAL REVISIONS...2129
    542B-1...2129
    542B-2...2131
    542B-3...2133
    542B-4...2135
    542B-5...2137
    542B-6...2139
    542B-7...2141
    542B-8...2143
6720184 (9-96) - 542B, 543 Operation & Maintenance Manual...2145
  CONTENTS...2147
    REFERENCE INFORMATION...2147
  FOREWORD...2149
    SERIAL NUMBER LOCATIONS...2151
      Loader Serial Number...2151
      Engine Serial Number Location...2151
    DELIVERY REPORT...2151
    BOBCAT SKID STEER LOADER IDENTIFICATION (542B)...2152
    BOBCAT SKID STEER LOADER IDENTIFICATION (543)...2153
  SAFETY...2155
    SAFETY INSTRUCTIONS...2157
      Safety Is Your Responsibility...2157
      Before Operating The Bobcat Loader...2158
      Safe Operation Needs A Qualified Operator...2158
    FIRE PREVENTION...2159
    SAFETY SIGNS (DECALS)...2160
  OPERATING INSTRUCTIONS...2163
    INSTRUMENT PANEL (One Piece)...2165
    INSTRUMENT PANEL (Three Piece)...2165
    CONTROLS...2166
    THROTTLE CONTROL...2166
    ENGINE STOP CONTROL (543)...2166
    STOPPING THE ENGINE (542B)...2166
    CHOKE CONTROL (542B)...2166
    PARKING BRAKE...2166
    STEERING LEVERS...2167
    HYDRAULIC CONTROLS...2168
      Foot Pedals...2168
      Lift Arm Operation...2168
      Float Position Operation...2168
      Tilt Operation (Bucket)...2168
      Auxiliary Lever Operation...2169
    DAILY INSPECTION...2169
    GETTING ON AND OFF THE LOADER...2171
    GETTING READY FOR OPERATION...2171
    STARTING THE ENGINE...2173
      Normal Starting Condition...2173
      Cold Starting Condition...2175
      Warming The Hydrostatic Transmission...2175
    ATTACHMENTS AND BUCKETS...2176
      Installation And Removal Of The Bucket...2176
    OPERATING PROCEDURE...2178
      Filling The Bucket...2179
      Emptying The Bucket...2179
      Digging Into The Ground...2180
      Leveling The Ground (Using Lift Arm Float Position)...2181
      Backfilling...2181
    PARKING THE BOBCAT LOADER...2182
    TRANSPORTING THE BOBCAT LOADER...2182
    TOWING THE LOADER...2183
    LIFTING THE LOADER...2184
  PREVENTIVE MAINTENANCE...2185
    SERVICE SCHEDULE...2187
    LIFT ARM SUPPORT DEVICE...2188
    OPERATOR CAB...2188
      Raising The Operator Cab...2188
      Lowering The Operator Cab...2189
    SEAT BAR RESTRAINT SYSTEM...2189
      Seat Bar Inspection...2190
      Seat Bar Maintenance...2190
    REAR DOOR...2191
      Adjustment...2191
    AIR CLEANER SERVICE (543)...2192
    AIR CLEANER SERVICE (542B)...2193
    FUEL SYSTEM...2194
      Filling The Fuel Tank...2194
      Fuel Filter (542B)...2194
      Fuel Filter (543)...2195
      Removing Air From The Fuel System (543)...2196
    ENGINE LUBRICATION SYSTEM...2197
      Replacement Of Engine Oil And Filter...2197
    COOLING SYSTEM...2199
      Rear Grill...2199
      Cleaning...2200
      Coolant Level...2200
      Coolant Replacement...2201
    ALTERNATOR BELT ADJUSTMENT...2202
    GOVENOR (542B)...2203
      Belt Adjustment...2203
      Govenor Oil Level...2203
    WIRING DIAGRAM...2204
    ELECTRICAL SYSTEM...2209
      Electrical System Service...2209
      Using And Extra Battery (Jump Starting)...2209
      Battery Replacement...2211
    HYDRAULIC / HYDROSTATIC FLOW CHART (542B, 543)...2212
    HYDRAULIC / HYDROSTATIC SYSTEM...2213
      Checking And Adding Fluid...2213
      Replacement Of The Hydraulic Filter Element...2213
      Removing The Hydraulic Fluid...2214
    SPARK ARRESTOR MUFFLER...2215
    FINAL DRIVE TRANSMISSION (CHAINCASE)...2216
    TIRE MAINTENANCE...2216
      Wheel Nuts...2217
      Tire Installation On A Rim...2217
      Tire Pressure...2217
    LUBRICATION OF THE BOBCAT LOADER...2217
    BOB-TACH...2219
    AUXILIARY CONTROL LOCKBOLT...2219
    PIVOT PINS...2219
    BRAKE PEDAL ADJUSTMENT...2219
  TROUBLESHOOTING...2221
    TROUBLESHOOTING THE ENGINE...2223
    TROUBLESHOOTING THE DRIVE SYSTEM...2224
    TROUBLE SHOOTING THE HYDRAULIC SYSTEM...2225
  MAJOR PARTS...2227
    MAIN FRAME...2229
    PANELS, SEAT, SEAT BAR & FUEL SYSTEM...2230
    DRIVE SYSTEM...2231
    HYDRAULIC SYSTEM...2232
    HYDROSTATIC SYSTEM...2233
    HAND CONTROLS AND CONTROL PEDALS...2234
    OPERATOR CAB ELECTRICAL SYSTEM...2235
    ENGINE ELECTRICAL SYSTEM...2236
    ENGINE & ATTACHING PARTS...2237
  SAFETY SIGNS...2239
    WARNING  - 6565980...2241
    SERVICE SCHEDULE - 6567875...2242
    WARNING - 6575855...2244
    WARNING - 6579510...2245
    IMPORTANT - 6560573...2246
    DANGER - 6579639...2246
  SPECIFICATIONS...2247
    OPERATION AND PERFORMANCE...2249
    ENGINE...2249
    HYDRAULIC SYSTEM...2250
    ELECTRICAL...2250
    DRIVE SYSTEM...2250
    CAPACITIES...2250
    TIRES...2250
  WARRANTY...2251
6720358 (11-89) - 542B Operation & Maintenance Manual...2253
  OPERATOR SAFETY WARNINGS...2255
  FOREWORD...2257
    CONTENTS...2257
    REFERENCE INFORMATION...2257
    SAFETY INSTRUCTIONS...2259
      Safety Is hte Operator& Responsibility...2259
      Before Operating The Bobcat Loader...2259
      Safe Operation Nedds A Qualified Operator...2260
    FIRE PREVENTION...2260
    SERIAL NUMBER LOCATIONS...2261
      Loader Serial Number...2261
      Engine Serial Number...2261
    DELIVERY REPORT...2261
    BOBCAT LOADER IDENTIFICATION...2262
    SAFETY SIGNS (DECALS)...2263
  OPERATING INSTRUCTIONS...2265
    INSTRUMENT PANEL...2267
      Three Piece...2267
    LEARNING THE CONTROLS...2268
    PARKING BRAKE...2268
    STEERING LEVERS...2269
    HYDRAULIC CONTROLS...2270
      Foot Pedals...2270
      Lift Arm Operation...2270
      Float Position Operation...2270
      Tilt Operation...2270
      Auxiliary Lever Operation...2271
    DAILY INSPECTION...2272
    GETTING READY FOR OPERATION...2273
    STARTING THE ENGINE...2275
      Normal Starting Condition...2275
      Cold Starting Condition...2276
      Warming The Hydraulic / Hydrostatic System...2276
    STOPPING THE ENGINE...2276
    ATTACHMENTS AND BUCKETS...2277
      Installation And Removal Of The Bucket...2278
    OPERATING PROCEDURES...2279
      Filling The Bucket...2280
      Emptying The Bucket...2280
      Digging Into The Ground...2281
      Leveling The Ground (Using Lift Arms In Float Position)...2282
      Backfilling...2282
    TRANSPORTING THE BOBCAT LOADER...2283
    PARKING THE BOBCAT LOADER...2283
    LIFTING THE BOBCAT LOADER...2284
    TOWING THE BOBCAT LOADER...2284
  PREVENTIVE MAINTENANCE...2285
    MAINTENANCE SAFETY...2286
    SERVICE SCHEDULE...2287
    LIFT ARM SUPPORT DEVICE...2288
    OPERATOR CAB...2288
      Raising The Operator Cab...2289
      Lowering The Operator Cab...2289
    SEAT BAR SYSTEM...2290
      Seat Bar Inspection...2290
      Seat Bar Maintenance...2290
    REAR DOOR...2291
      Opening The Rear Door...2291
      Adjusting The Rear Door...2291
    AIR CLEANER SERVICE...2292
    FUEL SYSTEM...2293
      Fuel Specifications...2293
      Filling The Fuel tank...2293
      Fuel Filter...2293
    ENGINE LUBRICATION SYSTEM...2294
      Replacement Of Engine Oil And Filter...2294
    COOLING SYSTEM...2295
      Rear Grill...2295
      Coolant Level...2296
      Removing Coolant From The Cooling System...2296
    GOVENOR...2297
      Belt Adjustment...2297
      Govenor Oil Level...2297
    ALTERNATOR BELT...2298
      Adjusting The Alternator Belt...2298
    ELECTRICAL SYSTEM...2299
      Description...2299
      Using An Extra Battery (Jump Starting)...2299
      Battery Removal And Installation...2301
    HYDRAULIC / HYDROSTATIC SYSTEM...2302
      Checking And Adding Fluid...2302
      Hydraulic / Hydrostatic Filter Replacement...2302
      Removing The Hydraulic Fluid...2303
    SPARK ARRESTOR MUFFLER...2304
    TIRE MAINTENANCE...2305
      Wheel Nuts...2305
      Tire Rotation...2305
      Tire Inflation...2305
    FINAL DRIVE TRANSMISSION (CHAINCASE)...2306
    LUBRICATION OF THE BOBCAT LOADER...2307
    PIVOT PINS...2308
    PARKING BRAKE PEDAL ADJUSTMENT...2308
    AUXILIARY RETAINER BOLT...2308
  TROUBLESHOOTING...2309
    TROUBLESHOOTING THE ENGINE...2311
    TROUBLESHOOTING THE DRIVE SYSTEM...2312
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...2313
  SAFETY SIGNS...2315
    WARNING - 6565980...2317
    WARNING - 6575855...2318
    WARNING - 6575854...2319
    IMPORTANT - 6560573...2320
    DANGER - 6575694...2320
  LOADER SPECIFICATIONS...2321
    OPERATIONS AND PERFORMANCE...2323
    ENGINE...2323
    HYDRAULIC SYSTEM...2324
    ELECTRICAL...2324
    DRIVE SYSTEM...2324
    CAPACITIES...2324
    TIRES...2324
  WARRANTY...2325
6722480 (3-99) - 543B Loader Operation & Maintenance Manual...2327
  OPERATOR SAFETY WARNINGS...2328
  CONTENTS...2329
  FOREWORD...2331
    SERIAL NUMBER LOCATIONS...2333
      Loader Serial Number...2333
      Engine Serial Number...2333
    DELIVERY REPORT...2333
    BOBCAT LOADER IDENTIFICATION...2334
  SAFETY...2335
    SAFETY INSTRUCTIONS...2337
      Safety Is The Operator& Responsibility...2337
      Before Operating The Bobcat Loader...2338
      Safe Operation Needs A Qualified Operator...2338
    FIRE PREVENTION...2339
    MACHINE SIGNS (DECALS)...2340
  OPERATING INSTRUCTIONS...2343
    INSTRUMENT PANEL...2345
    EMGINE SPEED CONTROL...2345
    ENGINE STOP CONTROL...2345
    PARKING BRAKE...2346
    STEERING LEVERS...2347
    HYDRAULIC CONTROLS...2348
      Foot Pedals...2348
      Lift Arm Operation...2348
      Tilt Operation (Bucket)...2348
      Auxiliary Hydraulics Operation (Optional)...2349
    DAILY INSPECTION...2350
    SEAT BAR RESTRAINT SYSTEM...2351
    GETTING READY FOR OPERATION...2352
    STARTING THE ENGINE...2353
      Normal Starting Condition...2353
      Cold Temperature Starting Condition...2355
      Warming The Hydraulic / Hydrostatic System...2355
    STOPPING THE ENGINE...2355
    ATTACHMENTS AND BUCKETS...2356
      Installation And Removal...2357
    OPERATING PROCEDURES...2358
      Filling The Bucket...2359
      Emptying The Bucket...2359
      Digging Into The Ground...2360
      Leveling The Ground (Using Lift Arms In Float Postion)...2361
      Backfilling...2361
    PARKING THE BOBCAT LOADER...2362
    TRANSPORTING THE BOBCAT LOADER...2362
    LIFTING THE LOADER...2363
    TOWING THE LOADER...2363
  PREVENTIVE MAINTENANCE...2365
    MAINTENANCE SAFETY...2366
    SERVICE SCHEDULE...2367
    LIFT ARM SUPPORT DEVICE...2368
    OPERATOR CAB...2368
      Raising The Operator Cab...2369
      Lowering The Operator Cab...2369
    SEAT BAR SYSTEM...2370
      Seat Bar Inspection...2370
      Seat Bar Maintenance...2370
    REAR DOOR...2371
      Adjustment...2371
    REAR GRILL...2372
    AIR CLEANER SERVICE...2373
    FUEL SYSTEM...2375
      Fuel Specifications...2375
      Filling The Fuel Tank...2375
      Fuel Filter...2375
      Removing Air From The Fuel System...2376
    ENGINE LUBRICATION SYSTEM...2377
      Replacing Oil And Filter...2377
    COOLING SYSTEM...2379
      Checking The Coolant Level...2379
      Cleaning The Cooling System...2379
      Removing Coolant From The Cooling System...2379
    ALTERNATOR BELT ADJUSTMENT...2381
    ELECTRICAL SYSTEM...2382
      Description...2382
      Electrical System Service...2382
      Using A Booster Battery ( Jump Starting)...2382
      Battery Removal And Installation...2383
    HYDRAULIC / HYDROSTATIC SYSTEM...2384
      Checking And Adding Fluid...2384
      Replacement Of The Hydraulic / Hydrostatic Filter Element...2385
      Removing The Hydraulic Fluid...2385
    SPARK ARRESTOR MUFFLER...2386
    TIRE MAINTENANCE...2387
      Wheel Nuts...2387
      Tire Rotation...2387
      Tire Inflation...2387
    FINAL DRIVE TRANSMISSION (CHAINCASE)...2388
      Checking And Adding Oil...2388
    LUBRICATION OF THE BOBCAT LOADER...2389
    BOB-TACH...2391
    PARKING BRAKE PEDAL...2391
      Adjustment...2391
    PIVOT PINS...2391
    AUXILIARY CONTROL LOCKBOLT...2392
    U-JOINTS LUBRICATION...2392
  TROUBLESHOOTING...2393
    TROUBLESHOOTING THE ENGINE...2395
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...2396
  MACHINE SIGN TRANSLATIONS...2399
    IMPORTANT - 6560573...2401
    WARNING - 6579511...2402
    SERVICE SCHEDULE - 6567875...2403
    WARNING - 6579510...2405
    WARNING - 6579528...2406
    DANGER - 6579639...2406
    WARNING - 6577754...2406
    DANGER - 6579509...2406
  SPECIFICATIONS...2407
    LOADER DIMENSIONS...2409
    OPERATIONS & PERFORMANCE...2409
    ENGINE...2409
    HYDRAULIC SYSTEM...2410
    ELECTRICAL...2410
    DRIVE SYSTEM...2410
    CAPACITIES...2410
    TIRES...2410
  WARRANTY...2411
6722584 (11-98) - 543 Loader Operation & Maintenance Manual...2413
  OPERATOR SAFETY WARNINGS...2415
  CONTENTS...2417
  FOREWORD...2419
    SERIAL NUMBER LOCATIONS...2421
      Loader Serial Number...2421
      Engine Serial Number...2421
    DELIVERY REPORT...2421
    BOBCAT LOADER IDENTIFICATION...2422
  SAFETY...2423
    SAFETY INSTRUCTIONS...2425
      Safety Is The Operator& Responsibility...2425
      Before Operating The Bobcat Loader...2426
      Safe Operation Needs A Qualified Operator...2426
    FIRE PREVENTION...2427
    MACHINE SIGNS (DECALS)...2428
  OPERATING INSTRUCTIONS...2431
    INSTRUMENT PANEL...2433
    ENGINE SPEED CONTROL...2433
    ENGINE STOP CONTROL...2433
    PARKING BRAKE...2434
    STEERING LEVERS...2435
    HYDRAULIC CONTROLS...2436
      Foot Pedals...2436
      Lift Arm Operation...2436
      Tilt Operation (Bucket)...2436
      Auxiliary Hydraulics Operation (Optional)...2437
    DAILY INSPECTION...2438
    SEAT BAR RESTRAINT SYSTEM...2439
    GETTING READY FOR OPERATION...2440
    STARTING THE ENGINE...2441
      Normal Starting Condition...2441
      Cold Temperature Starting Condition...2443
      Warming The Hydraulic / Hydrostatic System...2443
    STOPPING THE ENGINE...2443
    ATTACHMENTS AND BUCKETS...2444
      Installation And Removal...2445
    OPERATING PROCEDURES...2446
      Filling The Bucket...2447
      Emptying The Bucket...2447
      Digging Into The Ground...2448
      Leveling The Ground (Using Lift Arms In Float Position)...2449
      Backfilling...2449
    PARKING THE BOBCAT LOADER...2450
    TRANSPORTING THE BOBCAT LOADER...2450
    LIFTING THE BOBCAT LOADER...2451
    TOWING THE BOBCAT LOADER...2451
  PREVENTIVE MAINTENANCE...2453
    MAINTENANCE SAFETY...2454
    SERVICE SCHEDULE...2455
    LIFT ARM SUPPORT DEVICE...2456
    OPERATOR CAB...2457
      Raising The Operator Cab...2457
      Lowering The Operator Cab...2457
    SEAT BAR SYSTEM...2458
      Seat Bar Inspection...2458
      Seat Bar Maintenance...2458
    REAR DOOR...2459
      Adjustment...2459
    REAR GRILL...2460
    AIR CLEANER SERVICE...2461
    FUEL SYSTEM...2463
      Fuel Specifications...2463
      Filling The Fuel Tank...2463
      Fuel Filter...2463
      Removing Air From The Fuel System...2464
    ENGINE LUBRICATION SYSTEM...2465
      Replacing Oil And Filter...2465
    COOLING SYSTEM...2467
      Cleaning The Cooling System...2467
      Removing Coolant From The Cooling System...2467
    ALTERNATOR BELT ADJUSTMENT...2469
    ELECTRICAL SYSTEM...2470
      Description...2470
      Electrical System Service...2470
      Using A Booster Battery (Jump Starting)...2470
      Battery Removal And Installation...2471
    HYDRAULIC / HYDROSTATIC SYSTEM...2472
      Checking And Adding Fluid...2472
      Replacement Of The Hydraulic / Hydrostatic Filter Element...2473
    SPARK ARRESTOR MUFFLER...2474
    TIRE MAINTENANCE...2475
      Tire Rotation...2475
      Tire Inflation...2475
    FINAL DRIVE TRANSMISSION (CHAINCASE)...2476
      Checking And Adding Oil...2476
    LUBRICATION OF THE BOBCAT LOADER...2477
    BOB-TACH...2479
    PARKING BRAKE PEDAL...2479
      Adjustment...2479
    PIVOT PINS...2479
    AUXILIARY CONTROL LOCKBOLT...2480
    U-JOINTS LUBRICATION...2480
  TROUBLESHOOTING...2481
    TROUBLESHOOTING THE ENGINE...2483
    TROUBLESHOOTING THE DRIVE SYSTEM...2484
    TROUBLESHOOTING THE HYDRAULIC SYSTEM...2485
  MACHINE SIGN TRANSLATIONS...2487
    IMPORTANT - 6560573...2489
    WARNING - 6579511...2490
    SERVICE SCHEDULE - 6567875...2491
    WARNING - 6579510...2493
    WARNING - 6579528...2494
    DANGER - 6579539...2494
    WARNING - 6577754...2494
    DANGER - 6579509...2494
  SPECIFICATIONS...2495
    LOADER DIMENSIONS...2497
    OPERATIONS & PERFORMANCE...2497
    ENGINE...2497
    HYDRAULIC SYSTEM...2498
    ELECTRICAL...2498
    DRIVE SYSTEM...2498
    CAPACITIES...2498
    TIRES...2498
  WARRANTY...2499
 
Bobcat Loaders 540, 542B, 543, 543B Repair Service Manuals