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

540 (S/N: 501012001 & Above) – 543 (S/N: 502412001 & Above) – 543B (S/N: 511111001 & Above)
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This workshop repair service manual PDF download for the 540, 543 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Loader 540, 543
540 (S/N: 501012001 & Above)
543 (S/N: 502412001 & Above)
543B (S/N: 511111001 & Above)

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6566532 (11–94)
Total Pages : 322

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

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS

PREVENTIVE MAINTENANCE
INTRODUCTION
Serial Number Identification
Loader Serial Number
Engine Serial Number
Delivery Report
SERVICE SCHEDULE
ENGINE SERVICE (General)
Air Cleaner Service (540)
Air Cleaner Service (543)
Fuel System
Replacement of the Engine Oil and Filter
Engine Cooling System (540)
Engine Cooling System (543)
ELECTRICAL SYSTEM
Electrical System Service
Using an Extra Battery (Booster Starting)
Installing New Battery
SPARK ARRESTOR MUFFLER
HYDRAULIC/HYDROSTATIC SYSTEM
Replacing The Hydraulic Filter Element
Checking & Adding Hydraulic/HydrostaticFluid
Removing The Hydraulic/Hydrostatic Fluid
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking/Adding Chaincase Fluid
TIRE MAINTENANCE
Tire Rotation
Wheel Nuts
LUBRICATION OF THE LOADER
Lubrication Of The Loader
ROLL OVER PROTECTION STRUCTURE (ROPS & FOPS)
Operator Cab
TRANSPORTING THE BOBCAT LOADER
Loading The Bobcat Loader
Fastening The Loader To The Transport Vehicle
Lifting The Loader
Towing The Loader
LIFT ARM SUPPORT DEVICE
Installing the Approved Lift Arm Support Device
STOPPING THE BOBCAT LOADER

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
TROUBLESHOOTING
HYDRAULIC SYSTEM INFORMATION
37° Flare Connections
Straight Thread O–Ring Fitting
Tubelines And Hoses
HYDRAULIC CONTROL VALVE
Relief Valve
Check The Relief Valve
Removal Of The Relief Valve
Installation Of The Relief Valve
Removal Of The Hydraulic Control Valve
Disassembly Of The Hydraulic Control Valve
Detent Mechanism
Assembling The Hydraulic Control Valve
Installing The Hydraulic Control Valve
HYDRAULIC CONTROL VALVE (MELROE)
Relief Valve
Check The Relief Valve
Adjusting The Relief Valve
Relief Valve Service
Installation Of A New Relief Valve
Removal Of The Hydraulic Control Valve (Melroe)
Disassembly Of The Control Valve
Inspection Of The Control Valve
Assembly Of The Control Valve
Installation Of The Control Valve
HYDRAULIC PUMP
Checking Output Of Hydraulic Pump
Removal Of The Hydraulic Pump
Disassembly Of The Hydraulic Pump
Inspection Of The Hydraulic Pump
Assembling The Hydraulic Pump
Installation To The Hydraulic Pump
Start–up Procedure For The Hydraulic Pump
LIFT CYLINDERS
Checking The Lift Cylinders
Removing The Lift Cylinder
Disassembly Of The Hydraulic Cylinder
Assembly Of The Hydraulic Cylinder
Installation Of The Lift Cylinder
TILT CYLINDER
Checking The Tilt Cylinder
Removing The Tilt Cylinder
Installation Of The Tilt Cylinder
HYDRAULIC/HYDROSTATIC RESERVOIR
Removing The Hydraulic/Hydrostatic Reservoir
Installation Of The Hydraulic/Hydrostatic Reservoir
OIL COOLER
Removing The Oil Cooler (540)
Installation Of The Oil Cooler (540)
Removing The Oil Cooler (543)
Installation Of The Oil Cooler (543)
10 MICRON FILTER BY–PASS VALVE
Remove The By–Pass Valve
Installation Of The By–Pass Valve
CONTROL PEDAL, LINKAGE AND LOCKS
Removing The Control Pedal
Installation Of The Control Pedal
Adjusting The Control Pedal
Pedal Lock Linkage

HYDROSTATIC SYSTEM
TROUBLESHOOTING
HYDROSTATIC SYSTEM INFORMATION
High Pressure Relief Replenishing Valves Function
STEERING LEVERS
Removing Steering Levers
Repairing The Steering Levers
Installing The Steering Levers
STEERING LINKAGE
Adjustment Of The Steering Linkage
Removing The Steering Linkage
Repairing The Pintle Lever
Installing The Steering Linkage
PORT BLOCK
Removing The Port Block
Installing The Port Block
By–Pass Valve
Charge By–Pass Valve
HYDROSTATIC MOTOR
Removing The Hydrostatic Motor
Motors With Keyed–Shaft
Motors With Splined–Shaft
Disassembly of the Hydrostatic Motor
Hydrostatic Motor Inspection
Assembly Of The Hydrostatic Motor
Installing The Hydrostatic Motor
Keyed–Shaft Motors
Splined–Shaft Motors
Start–Up Procedure For The Hydrostatic Motor
HYDROSTATIC PUMP
Checking The High Pressure Relief Replenishing Valves
Checking The Charge Pressure
Removing The Hydrostatic Pump
Disassembly Of The Hydrostatic Pump
Inspection Of The Hydrostatic Pumps
Assembling The Hydrostatic Pumps
Installing The Hydrostatic Pumps
Start–Up Procedure For The Hydrostatic Pump
TOWING THE BOBCAT LOADER
Installation Of The Tool For The High Pressure Relief Valves

DRIVE SYSTEM
PARKING BRAKE
Parking Brake Adjustment
Parking Brake Removal
Parking Brake Inspection
Parking Brake Installation
FINAL DRIVE CHAINS
Remove The Drive Chain(s)
Installing The Drive Chain(s)
AXLES AND BEARINGS
Removing Axle(s) and Bearings
Assembly Of The Axle
Axle And Bearing Installation
CHAINCASE FLUID
Replacing Chaincase Fluid

MAIN FRAME
OPERATOR CAB
Raising The Operator Cab
Lowering The Operator Cab
Jumper Start Switch
Removing The Operator Cab
Removing The Gas Cylinder
Installing The Operator Cab
LIFT ARMS
Removing The Lift Arms
Installing The Lift Arms
BOB–TACH
Removing The Bob–Tach
Disassembly Of The Bob–Tach
Assembly Of The Bob–Tach
Installing The Bob–Tach
REAR DOOR
Removing The Rear Door
Installing The Rear Door
Adjusting The Rear Door Latch
FUEL TANK
Removing The Fuel Tank
Installing The Fuel Tank
SEAT BAR
Removal And Installation
SEAT BAR SYSTEM
Seat Bar Inspection
Seat Bar Maintenance
PEDAL LOCK LINKAGE
Adjustment
REAR WINDOW
Installing Rear Window

ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
TROUBLESHOOTING
ELECTRICAL SYSTEM INFORMATION
Electrical Circuitry
Safety Procedures For The Batteries
Precautions For The Alternator
BATTERY
Removing The Battery
Installing The Battery
WIRE HARNESS FOR THE OPERATOR CAB
Removing The Wire Harness For The Operator Cab
Installing The Wire Harness For The Operator Cab
WIRE HARNESS FOR THE ENGINE
ALTERNATOR SYSTEM (540)
Checking The Alternator
Replacing The Stator
ALTERNATOR SYSTEM (543)
Adjusting The Alternator Belt
Alternator Output Test (New Style)
Rectifier (Diode) Test (New Style)
Alternator Regulator Test (New Style)
Checking The Alternator (Early Models)
Parts Identification (New Style)
Disassembly And Assembly (New Style)
Stator Continuity Test
Stator Ground Test
Rotor Continuity Test
Rotor Ground Test
Rectifier Continuity (Diode) Test
Removing The Alternator (Early Models)
Repairing The Alternator (Early Models)
Installing The Alternator (Early Models)
STARTER (540)
Checking The Starter
Removing The Starter
Repairing The Starter
STARTER (543)
Checking The Starter
Removing The Starter
Repairing The Starter
Installing The Starter

ENGINE SERVICE
ENGINE SERVICE (540) KOHLER
TROUBLESHOOTING
CHECKS AND ADJUSTMENTS FOR THE ENGINE
Engine Oil Pressure
Valve Clearance
Compression
Throttle And Governor Linkage
Ignition System
Spark Plugs
CARBURETOR & FUELSHUT–OFF SOLENOID
Removing The Carburetor
Disassembly And Inspection Of The Carburetor
Assembly Of The Carburetor
Fuel Shut–off Solenoid
Non–Metallic Bodied Fuel Pumps
GOVERNOR
Removing The Governor
Installing The Governor
ENGINE AND HEAT SHIELD
Removing The Engine
Installing The Engine
Removing The Heat Shield
Installing The Heat Shield
RECONDITIONING THEVALVES
Repair Of The Valves And Guides
TIMING COVER, TIMING GEARS AND CAMSHAFT
Timing Cover
Timing Gears
Camshaft And Tappets
OIL PUMP AND RELIEF VALVE
Relief Valve
Oil Pump
Adjusting Gear Clearance For The Oil Pump
PISTONS, RODS AND CRANKSHAFT
Removing Pistons, Rods And Crankshaft
Crankshaft Bearing And End Play
CYLINDER HEAD
INTAKE AND EXHAUST MANIFOLD
FLYWHEEL
ENGINE SERVICE (543 & 543B) KUBOTA
TROUBLESHOOTING
FUEL SYSTEM
Replacing The Fuel Filter
To Remove The Air From The Fuel System
Fuel Injection Pump
Checking The Injection Pump
Installation
Timing The Fuel Injection Pump
Fuel Injector Nozzles
Removal
Checking The Fuel Injector Nozzles
Installation
Checking Glow Plugs
ENGINE AND ATTACHING PARTS
Removing The Engine
Installing The Engine
Engine Muffler
Engine Radiator Removal
Engine Radiator Installation
Engine Blower Housing Removal
Engine Blower Housing Installation
Engine Blower Fan And Flywheel Removal
Engine Blower Fan And Flywheel Installation
CYLINDER HEAD
Removing The Cylinder Head
Disassembly Of The Cylinder Head
Servicing The Cylinder Head
Assembly Of The Cylinder Head
Installing The Cylinder Head
Adjusting the Compression Release Mechanism
REPAIRING THE ENGINE
Removing The Gear Case
Removing The Timing Gear, Camshaft & Oil Pump
Removing Pistons And Crankshaft
Servicing The Timing Gear And The Camshaft
Servicing The Connecting Rods And Pistons
Servicing The Crankshaft
Servicing The Cylinder Liners
Servicing The Oil Pump
Servicing The Water Pump
ASSEMBLY OF THE ENGINE
Installing The Crankshaft
Installing The Pistons
Installing The Camshaft And Timing Gears
Installing The Gear Case Cover

TECHNICAL DATA
(540) KOHLER LOADER SPECIFICATIONS
Operation & Performance
Engine
Loader Hydraulics
Electrical
Drive System
Capacities
Tires
ENGINE SPECIFICATIONS – 540 LOADER (KOHLER)
Engine (General)
Cylinder Bore
Crankshaft
Camshaft
Connecting Rod
Piston, Pin And Rings
Valves, Guides & Tappets
Engine Torque
543 & 543B KUBOTA LOADER SPECIFICATIONS
Operation & Performance
Engine
Loader Hydraulics
Electrical
Drive System
Capacities
Tires
ENGINE SPECIFICATIONS – 543-543B LOADER
Fuel Injector Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Rocker Arms
Camshaft
Cylinders
Piston Rings
Piston
Crankshaft
Oil Pump
Thermostat
Engine Torque
Grinding Specifications for the Crankshaft
TORQUE SPECIFICATIONS
Engine Group – 540 Loader
Engine Group – 543 Loader
Fuel System Group
Steering Levers & Panel Group
Bob–Tach & Lift Arm Group
Seat Bar & Pedal Group
Brake, Chaincase & Axle Group
Hydraulic Group
Operator Cab, Main Frame & Rear Door Group
Hydrostatic Group–540 Loader
Hydrostatic Group–543 Loader
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Hydraulic/Hydrostatic Fluid
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION
STANDARD TORQUE SPECIFICATIONS FOR BOLTS

SERVICE MANUAL REVISIONS
540–3
540–4
540–5
540–6
540–7
540–8
540–9
540–11
540–13
540–14
540–15
540–16
540–17
540–1 Thru 540–17
540–18
540–19

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