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

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This workshop repair service manual PDF download for the 542B Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Loader 542B

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

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

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

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MAINTENANCE SAFETY
CONTENTS
FOREWORD
SERIAL NUMBER LOCATIONS
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION

PREVENTIVE MAINTENANCE
SERVICE SCHEDULE
PREVENTIVE MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM STOP
Procedure
TRANSPORTING THE BOBCAT LOADER
Procedure
OPERATOR CAB
Operator Cab Fasteners
Raising And Lowering The Operator Cab
SEAT BAR SYSTEM
Seat Bar Description
Seat Bar Inspection
Seat Bar Maintenance
USING AN EXTRA BATTERY (JUMP STARTING)
Procedure
AIR CLEANER
Replacement Of Filter Element
FUEL SYSTEM
Filling The Fuel Tank
Fuel Filter
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Replacement Of Engine Oil And Filter
COOLING SYSTEM
Rear Grill
Coolant Level
Removing Coolant From The Cooling System
HYDRAULIC / HYDROSTATIC SYSTEM
Checking And Adding Fluid
Replacement Of The Hydraulic Filter Element
Removing The Hydraulic Fluid
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking Oil Level
TIRE MAINTENANCE
Wheel Nuts
Tire Rotation
Tire Inflation
LUBRICATION OF THE LOADER
Procedure
REMOTE START SWITCH
Procedure

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
TROUBLESHOOTING
HYDRAULIC SYSTEM INFORMATION
Flare Connections
Straight Thread O-Ring Fitting
Tubelines And Hoses
LIFT CYLINDER
Checking The Lift Cylinder(s)
Removal And Installation
TILT CYLINDER
Checking The Tilt Cylinder
Removal And Installation
Rod End Seal
HYDRAULIC CONTROL VALVE
Checking The Main Relief Valve With Auxiliary Couplers (Opt.)
Checking The Main Relief Valve Without Auxiliary Hydraulics
Main Relief Valve Removal And Installation
Adjusting The Main Relief Valve
Removal And Installation
HYDRAULIC PUMP
Checking The Output Of The Hydraulic Pump
Removal And Installation
PORT BLOCK
Removal And Installation
Charge By-Pass Valve
FILTER BY-PASS VALVE
Removal And Installation
HYDRAULIC FLUID RESERVOIR
Removal And Installation
HYDRAULIC CONTROL PEDALS
Removal And Installation
Adjustment
PEDAL LOCK LINKAGE
Installation
Adjustment

HYDROSTATIC SYSTEM
TROUBLESHOOTING
HYDROSTATIC SYSTEM INFORMATION
High Pressure Relief/Rreplenishing Valve Function
FRONT PANEL
Removal And Installation
STEERING LEVERS
Removal And Installation
Repairing The Steering Levers
STEERING LINKAGE
Steering Linkage Adjustment
Removal And Installation
Repairing The Pintle Lever
HYDROSTATIC MOTOR
Removal And Installation
Start-Up Procedure
HYDROSTATIC PUMP
Checking The Charge Pressure
Checking High Pressure Relief/Replenishing Valves
Removal And Installation
High Pressure Hose Routing
Start-Up Procedure
TOWING THE LOADER
Procedure

DRIVE SYSTEM
PARKING BRAKE
Adjustment
Removal And Installation
Block And Pucks
AXLES, SEALS AND BEARINGS
Removal
Installation
FINAL DRIVE CHAIN
Removal
Installation
CHAINCASE FLUID
Replacing The Chaincase Fluid

MAIN FRAME
OPERATOR CAB
Removal And Installation
OPERATOR CAB GAS CYLINDER
Removal And Installation
REAR DOOR
Door Latch Adjustment
Removal And Installation
LIFT ARMS
Removal And Installation
BOB-TACH
Removal And Installation
Tilt Cylinder Rod End Seal
Bob-Tach Wedges
FUEL TANK
Removal And Installation

ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Description
TROUBLESHOOTING
BATTERY
Checking The Battery
Removal And Installation
ALTERNATOR
Checking The Alternator Output
Checking The Alternator Regulator
Removal And Installation
Disassenbly And Assembly
Checking Rotor, Stator And Rectifier
STARTER
Checking The Starter
Removal And Installation
Disassembly And Assembly
Cleaning And Inspection
Replacing The Brushes

ENGINE SERVICE
TROUBLESHOOTING
VALVE CLEARANCE
Adjustment
BELT SHIELD
Removal And Installation
FUEL LIFT PUMP
Checking
Removal And Installation
CARBURETOR
Description
Operation
Removal And Installation
Disassembly And Assembly
Inspection
IGNITION SYSTEM
Description
Troubleshooting
Ignition Timing Procedure
DISTRIBUTOR
Removal And Installation
Disassembly And Assembly
Checking The Distibutor
Spark Advance Test
IGNITION – DISTRIBUTORLESS
Description
Engine, Speed, Load & Temperature
Service Adjustments And Checks
Coil Removal And Installation
Engine Speed Sensor
Engine Coolant Temperature Sensor
GOVENOR
Belt Adjustment
Govenor Oil Level
Removal And Installation
Adjusting The Govenor
ENGINE MUFFLER
Removal And Installation
RADIATOR
Removal And Installation
ENGINE
Removal And Installation
OIL COOLER AND BLOWER HOUSING
Removal And Installation
FLYWHEEL AND U-JOINT
Removal And Installation
Flywheel Ring Gear
ROCKER ARMS
Removal And Installation
Disassembly And Assembly
Inspection
CYLINDER HEAD
Removal And Installation
Cleaning
Inspection
VALVES, VALVE GUIDES & SPRINGS
Removal
Valve Guides
Reconditioning The Valve And Valve Seat
Valve Springs
PISTON AND CONNECTING ROD
Removal And Installation
Fitting Pistons
Piston Rings
Piston Pin
Connecting Rods
CYLINDER BLOCK
Cleaning
Inspection
Refinishing Cylinder Bores
CRANKSHAFT FRONT OIL SEAL
Removal
Installation
CRANKSHAFT REAR OIL SEAL
Removal
Installation
CRANKSHAFT AND MAIN BEARINGS
Inspection
Refinishing Crankshaft Journals
Fitting Bearing with Plastigage
Crankshaft End Play
TIMING CHAIN COVER
Removal And Installation
TIMING CHAIN AND SPROCKETS
Removal
Inspection
Installation
CAMSHAFT
Checking Camshaft Lobe Lift
Removal And Installation
Inspection
Camshaft Bearing
Camshaft End Play
PUCH RODS AND TAPPETS
Inspecting The Push Rods
Inspecting The Tappet
OIL PAN
Removal
Cleaning And Inspection
Installation
OIL PUMP
Disassembly
Inspection
Assembly

TECHNICAL DATA
LOADER/ENGINE SPECIFICATIONS (S/N 11999 & BELOW)
SPECIFICATIONS
OPERATION AND PERFORMANCE
ENGINE
ELECTRICAL
DRIVE SYSTEM
HYDRAULIC SYSTEM
CAPACITIES
TIRES
ENGINE SPECIFICATIONS (S/N 11999 & BELOW)
Cylinder Block
Crankshaft
Connecting Rod
Pistons
Piston Pins
Piston Rings
Cylinder Head
Valves
Valve Springs
Tappets
Rocker Arms & Shaft
Oil Pump
Camshaft
Ignition System – Solid State
Distributor Advance
Belt Tension
Fuel Pump
Engine Torque
LOADER TORQUES
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
DECIMAL AND MILLIMETER EQUIVALENTS
U.S. TO METRIC CONVERSION
STANDARD TORQUE SPECIFICATIONS FOR BOLTS
LOADER/ENGINE SPECIFICATIONS (S/N 12001 & ABOVE)
SPECIFICATIONS
OPERATION AND PERFORMANCE
ENGINE
HYDRAULIC SYSTEM
ELECTRICAL
DRIVE SYSTEM
CAPACITIES
TIRES
ENGINE SPECIFICATIONS
Cylinder Block
Crankshaft
Connecting Rod
Pistons
Piston Pins
Piston Rings
Cylinder Head
Valves
Valve Springs
Tappets
Rocker Arms & Shaft
Oil Pump
Camshaft
Ignition System – Distributorless
Belt Tension
Fuel Pump
Engine Torque

SERVICE MANUAL REVISIONS
542B-1
542B-2
542B-3
542B-4
542B-5
542B-6
542B-7

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