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

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

APPLICABLE MODELS :

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

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

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

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

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MAINTENANCE SAFETY
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS

PREVENTIVE MAINTENANCE
INTRODUCTION
Serial Number Identification
Loader Serial Number
Engine Serial Number
Pre–Delivery Inspection
Thirty Hour Inspection
SERVICE SCHEDULE
ENGINE SERVICE (General)
Air Cleaner Service
Fuel System
Engine Lubrication System
Replacement Of The Engine Oil And Filter
Engine Cooling System
ELECTRICAL SYSTEM
Electrical System Service
Using An Extra Battery (Booster Starting)
Installing New Battery
HYDRAULIC/HYDROSTATIC FLUID
Replacing The Hydraulic/Hydrostatic Filter
Checking And Adding Hydraulic/Hydrostatic Fluid
Removing The Hydraulic/Hydrostatic Fluid
FINAL DRIVE TRANSMISSION (Chaincase)
Checking Chaincase Fluid
SPARK ARRESTOR MUFFLER
Cleaning The Spark Arrestor Muffler
OPERATOR GUARD
LUBRICATION OF THE LOADER
TRANSPORTING THE BOBCAT LOADER
Loading The Bobcat Loader
Fastening The Loader To TheTransport Vehicle
LIFT ARM STOP
STOPPING THE BOBCAT LOADER

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

HYDROSTATIC SYSTEM
TROUBLESHOOTING
HYDROSTATIC SYSTEM INFORMATION
High Pressure Relief Replenishing Valves Function
STEERING LEVERS
Removing Steering Levers
Repairing The Steering Levers
Installing The Steering Levers
STEERING LINKAGE
Adjustment Of The Steering Linkage
Removing The Steering Linkage
Repairing The Pintle Lever
Installing The Steering Linkage
PORT BLOCK
Removing The Port Block
Installing The Port Block
By–Pass Valve
HYDROSTATIC MOTOR
Removing The Hydrostatic Motor
Disassembly Of The Hydrostatic Motor
Inspection Of The Hydrostatic Motor
Assembling The Hydrostatic Motor
Installing The Hydrostatic Motor
Start–Up Procedure For The Hydrostatic Motor
HYDROSTATIC PUMP
Checking The High Pressure Relief Replenishing Valves
Checking The Charge Pressure
Cold Weather By–Pass Valve
Removing The Hydrostatic Pumps
Disassembly Of The Hydrostatic Pumps
Inspection Of The Hydrostatic Pumps
Assembling The Hydrostatic Pumps
Installing the Hydrostatic Pumps
Hydrostatic Pump Start–Up Procedure

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

MAIN FRAME
OPERATOR GUARD
Raising The Operator Guard
Lowering The Operator Guard
Jumper Start Switch
Removing The Operator Guard
Installing The Operator Guard
LIFT ARMS
Removing The Lift Arms
Installing The Lift Arms
BOB–TACH
Removing The Bob–Tach
Disassembly Of The Bob–Tach
Assembly Of The Bob–Tach
Installing The Bob–Tach
REAR DOOR
Removing The Rear Door (Early Model)
Removing The Rear Door (Later Models)
Installing The Rear Door
Adjusting The Rear Door Latch
FUEL TANK
Removing The Fuel Tank
Installing The Fuel Tank

ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
TROUBLESHOOTING
ELECTRICAL SYSTEM INFORMATION
Electrical Circuitry
Safety Procedures For The Batteries
Precautions For The Alternator
BATTERY
Removing The Battery
Installing The Battery
WIRE HARNESS FOR THE OPERATOR GUARD
Removing The Wire Harness For The Operator Guard
Installing The Wire Harness For The Operator Guard
WIRE HARNESS FOR THE ENGINE
ALTERNATOR SYSTEM (540)
Checking the A.C. Voltage
Replacement Of The Stator
ALTERNATOR SYSTEM (543)
Belt Adjustment For The Alternator
Checking The Alternator
Removing The Alternator
Repairing The Alternator
Installing The Alternator
STARTER (540)
Checking The Starter
Removing The Starter
Repairing The Starter
STARTER (543)
Checking The Starter
Removing The Starter
Repairing The Starter
Installing The Starter

ENGINE SERVICE
540 KOHLER ENGINE SERVICE
TROUBLESHOOTING
CHECKS & ADJUSTMENTS
Oil Pressure
Valve Clearance
Compression
Throttle And Governor Linkage
Ignition System
Spark Plugs
CARBURETOR & FUEL SHUT–OFF SOLENOID
Removing The Carburetor
Disassembly And Inspection Of The Carburetor
Assembly Of The Carburetor
Fuel Shut–off Solenoid
GOVERNOR
Removing The Governor
Installing The Governor
ENGINE AND HEAT SHIELD
Removing The Engine
Installation Of The Engine
Removing The Heat Shield
Installing The Heat Shield
RECONDITIONING THE VALVES
Repair Of The Valves And Guides
TIMING COVER, TIMING GEARS AND CAMSHAFT
Timing Cover
Timing Gears
Camshaft And Tappets
OIL PUMP AND RELIEF VALVE
Relief Valve
Oil Pump
Adjusting Gear Clearance For The Oil Pump
PISTONS, RODS AND CRANKSHAFT
Removing Pistons, Rods And Crankshaft
Crankshaft Bearing And End Play
CYLINDER HEAD
INTAKE AND EXHAUST MANIFOLD
FLYWHEEL
543 ISUZU ENGINE SERVICE
TROUBLESHOOTING
FUEL SYSTEM
Fuel Filter
Removing The Air From The Fuel System
Fuel Lift Pump
Removal Of The Fuel Injection Pump
Fuel Injection Pump Drive Gear
Installation And Timing Of The Fuel Injection Pump
Fuel Injection Pump Reservoir
Fuel Injector Nozzles
Removing The Fuel Injector Nozzles
Checking The Fuel Injector Nozzles
Disassembly Of The Fuel Injector Nozzle
Inspection Of The Fuel Injector Nozzle
Assembling The Fuel Injectors Nozzle
nstallation Of The Fuel Injector Nozzles
ENGINE, BLOWER HOUSING AND RADIATOR
Removing The Engine
Installing The Engine
Installing The Blower Housing
Removing The Radiator
Installation Of The Radiator
ENGINE OVERHAUL
Disassembly Of The Engine
ROCKER ARMS AND SHAFT
Disassembly Of The Rocker Arms
Inspection Of The Rocker Arms
CYLINDER HEAD
Disassembly Of The Cylinder Head
Inspection Of The Cylinder Head
Inspection Of The Combustion Chambers
Inspection And Correction Of The Valves & Guides
Inspection Of The Valve Springs
Inspection Of The Push Rods And Tappets
Installation Of The Hot Plugs
Assembly Of The Valve System
CYLINDER BLOCK
Inspection Of The Cylinder Block
Correction Of The Cylinder Bores
PISTONS AND PISTON RINGS
Disassembly Of The Piston And Rings
Inspection Of The Pistons
Inspection Of The Connecting Rods & Bearings
Assembly Of The Piston & Connecting Rod
Inspection Of The Connecting Rod Bearings
CRANKSHAFT
Inspection Of The Crankshaft And Bearings
CAMSHAFT
Inspection Of The Camshaft
TIMING GEAR
Inspection Of The Timing Gear
MANIFOLD ASSEMBLY
Inspection Of The Manifold Assembly
OIL PUMP AND OIL FILTER ASSEMBLY
Disassembly Of The Oil Pump
Inspection Of The Oil Pump
Oil Filter Assembly
Inspection Of The Oil Filter Assembly
WATER PUMP
Disassembly Of The Water Pump
Inspection Of The Water Pump
Assembly Of The Water Pump
ASSEMBLY OF THE ENGINE
ENGINE FLYWHEEL
Removing The Flywheel
Installing The Flywheel

TECHNICAL DATA
540 LOADER SPECIFICATIONS
Specifications
Engine
Loader Hydraulics
Electrica
Drive System
Capacities
Tires
543 LOADER SPECIFICATIONS
Specifications
Engine
Loader Hydraulics
Electrical
Drive System
Capacities
Tires
ENGINE SPECIFICATIONS
540 LOADER (KOHLER)
Engine (General)
Cylinder Bore
Crankshaft
Camshaft
Connecting Rod
Piston, Pin & Rings
Valves, Guides & Tappets
Engine Torque
543 LOADER (ISUZU)
Cylinder Block
Cylinder Head
Piston
Piston Ring
Connecting Rod
Crankshaft
Camshaft
Timing Gear
Valve
Valve Spring
Tappet
Oil Pump and Relief Valve
Water Pump
Fuel Lift Pump
Fuel Injector
Engine Torque
TORQUE SPECIFICATIONS
Engine Group – 540 Loader
Engine Group – 543 Loader
Engine Group – 543 Loader
Seat Bar, Fuel Tank & Panel Group
Steering Levers, Linkage & Pedal Group
Mainframe Group
Hydrostatic Group – 540 Loader
Hydrostatic Group – 543 Loader
Hydraulic Group
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Hydraulic/Hydrostatic Fluid
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION
STANDARD TORQUE SPECIFICATIONS FOR BOLTS

ALPHABETICAL INDEX