Bobcat 540 543 543B Loader Service Manual 6566532 (6-12) – PDF DOWNLOAD

Description

Bobcat 540 543 543B Loader Service Manual 6566532 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 540 543 543B Loader Service Manual 6566532 (6-12) – PDF DOWNLOAD

Language : English
Pages : 324
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 540 543 543B Loader Service Manual 6566532 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
PREVENTIVE MAINTENANCE 13
INTRODUCTION 15
Serial Number Identification 15
Loader Serial Number 15
Engine Serial Number 15
Delivery Report 15
SERVICE SCHEDULE 16
ENGINE SERVICE (General) 17
Air Cleaner Service (540) 17
Air Cleaner Service (543) 18
Fuel System 19
Replacement of the Engine Oil and Filter 20
Engine Cooling System (540) 23
Engine Cooling System (543) 24
ELECTRICAL SYSTEM 25
Electrical System Service 25
Using an Extra Battery (Booster Starting) 25
Installing New Battery 27
SPARK ARRESTOR MUFFLER 28
HYDRAULIC/HYDROSTATIC SYSTEM 29
Replacing The Hydraulic Filter Element 29
Checking & Adding Hydraulic/HydrostaticFluid 30
Removing The Hydraulic/Hydrostatic Fluid 32
FINAL DRIVE TRANSMISSION (CHAINCASE) 32
Checking/Adding Chaincase Fluid 32
TIRE MAINTENANCE 33
Tire Rotation 33
Wheel Nuts 33
LUBRICATION OF THE LOADER 34
Lubrication Of The Loader 34
ROLL OVER PROTECTION STRUCTURE (ROPS & FOPS) 34
Operator Cab 34
TRANSPORTING THE BOBCAT LOADER 35
Loading The Bobcat Loader 35
Fastening The Loader To The Transport Vehicle 35
Lifting The Loader 36
Towing The Loader 36
LIFT ARM SUPPORT DEVICE 37
Installing the Approved Lift Arm Support Device 37
STOPPING THE BOBCAT LOADER 37
HYDRAULIC SYSTEM 39
HYDRAULIC / HYDROSTATIC SCHEMATICS 41
TROUBLESHOOTING 49
HYDRAULIC SYSTEM INFORMATION 50
37° Flare Connections 50
Straight Thread O–Ring Fitting 50
Tubelines And Hoses 50
HYDRAULIC CONTROL VALVE 51
Relief Valve 51
Check The Relief Valve 51
Removal Of The Relief Valve 52
Installation Of The Relief Valve 52
Removal Of The Hydraulic Control Valve 53
Disassembly Of The Hydraulic Control Valve 54
Detent Mechanism 55
Assembling The Hydraulic Control Valve 56
Installing The Hydraulic Control Valve 58
HYDRAULIC CONTROL VALVE (MELROE) 59
Relief Valve 59
Check The Relief Valve 59
Adjusting The Relief Valve 60
Relief Valve Service 60
Installation Of A New Relief Valve 61
Removal Of The Hydraulic Control Valve (Melroe) 61
Disassembly Of The Control Valve 62
Inspection Of The Control Valve 64
Assembly Of The Control Valve 65
Installation Of The Control Valve 67
HYDRAULIC PUMP 67
Checking Output Of Hydraulic Pump 69
Removal Of The Hydraulic Pump 69
Disassembly Of The Hydraulic Pump 70
Inspection Of The Hydraulic Pump 71
Assembling The Hydraulic Pump 71
Installation To The Hydraulic Pump 72
Start–up Procedure For The Hydraulic Pump 72
LIFT CYLINDERS 73
Checking The Lift Cylinders 73
Removing The Lift Cylinder 73
Disassembly Of The Hydraulic Cylinder 74
Assembly Of The Hydraulic Cylinder 75
Installation Of The Lift Cylinder 77
TILT CYLINDER 78
Checking The Tilt Cylinder 78
Removing The Tilt Cylinder 79
Installation Of The Tilt Cylinder 80
HYDRAULIC/HYDROSTATIC RESERVOIR 80
Removing The Hydraulic/Hydrostatic Reservoir 80
Installation Of The Hydraulic/Hydrostatic Reservoir 81
OIL COOLER 81
Removing The Oil Cooler (540) 81
Installation Of The Oil Cooler (540) 82
Removing The Oil Cooler (543) 82
Installation Of The Oil Cooler (543) 82
10 MICRON FILTER BY–PASS VALVE 82
Remove The By–Pass Valve 82
Installation Of The By–Pass Valve 83
CONTROL PEDAL, LINKAGE AND LOCKS 83
Removing The Control Pedal 83
Installation Of The Control Pedal 83
Adjusting The Control Pedal 84
Pedal Lock Linkage 84
HYDROSTATIC SYSTEM 87
TROUBLESHOOTING 89
HYDROSTATIC SYSTEM INFORMATION 90
High Pressure Relief Replenishing Valves Function 90
STEERING LEVERS 91
Removing Steering Levers 91
Repairing The Steering Levers 92
Installing The Steering Levers 92
STEERING LINKAGE 93
Adjustment Of The Steering Linkage 93
Removing The Steering Linkage 94
Repairing The Pintle Lever 95
Installing The Steering Linkage 95
PORT BLOCK 96
Removing The Port Block 96
Installing The Port Block 96
By–Pass Valve 97
Charge By–Pass Valve 97
HYDROSTATIC MOTOR 97
Removing The Hydrostatic Motor 98
Motors With Keyed–Shaft 98
Motors With Splined–Shaft 98
Disassembly of the Hydrostatic Motor 99
Hydrostatic Motor Inspection 102
Assembly Of The Hydrostatic Motor 103
Installing The Hydrostatic Motor 109
Keyed–Shaft Motors 109
Splined–Shaft Motors 109
Start–Up Procedure For The Hydrostatic Motor 109
HYDROSTATIC PUMP 110
Checking The High Pressure Relief Replenishing Valves 110
Checking The Charge Pressure 111
Removing The Hydrostatic Pump 111
Disassembly Of The Hydrostatic Pump 113
Inspection Of The Hydrostatic Pumps 116
Assembling The Hydrostatic Pumps 117
Installing The Hydrostatic Pumps 120
Start–Up Procedure For The Hydrostatic Pump 122
TOWING THE BOBCAT LOADER 124
Installation Of The Tool For The High Pressure Relief Valves 124
DRIVE SYSTEM 125
PARKING BRAKE 127
Parking Brake Adjustment 127
Parking Brake Removal 128
Parking Brake Inspection 131
Parking Brake Installation 131
FINAL DRIVE CHAINS 135
Remove The Drive Chain(s) 135
Installing The Drive Chain(s) 136
AXLES AND BEARINGS 137
Removing Axle(s) and Bearings 137
Assembly Of The Axle 138
Axle And Bearing Installation 139
CHAINCASE FLUID 140
Replacing Chaincase Fluid 140
MAIN FRAME 141
OPERATOR CAB 143
Raising The Operator Cab 143
Lowering The Operator Cab 144
Jumper Start Switch 145
Removing The Operator Cab 146
Removing The Gas Cylinder 147
Installing The Operator Cab 149
LIFT ARMS 149
Removing The Lift Arms 149
Installing The Lift Arms 150
BOB–TACH 151
Removing The Bob–Tach 151
Disassembly Of The Bob–Tach 152
Assembly Of The Bob–Tach 153
Installing The Bob–Tach 154
REAR DOOR 155
Removing The Rear Door 155
Installing The Rear Door 156
Adjusting The Rear Door Latch 156
FUEL TANK 156
Removing The Fuel Tank 156
Installing The Fuel Tank 157
SEAT BAR 157
Removal And Installation 157
SEAT BAR SYSTEM 158
Seat Bar Inspection 158
Seat Bar Maintenance 158
PEDAL LOCK LINKAGE 159
Adjustment 159
REAR WINDOW 159
Installing Rear Window 159
ELECTRICAL SYSTEM 161
ELECTRICAL SCHEMATICS 164
TROUBLESHOOTING 177
ELECTRICAL SYSTEM INFORMATION 178
Electrical Circuitry 178
Safety Procedures For The Batteries 178
Precautions For The Alternator 179
BATTERY 179
Removing The Battery 179
Installing The Battery 180
WIRE HARNESS FOR THE OPERATOR CAB 180
Removing The Wire Harness For The Operator Cab 180
Installing The Wire Harness For The Operator Cab 181
WIRE HARNESS FOR THE ENGINE 181
ALTERNATOR SYSTEM (540) 182
Checking The Alternator 182
Replacing The Stator 184
ALTERNATOR SYSTEM (543) 184
Adjusting The Alternator Belt 184
Alternator Output Test (New Style) 186
Rectifier (Diode) Test (New Style) 186
Alternator Regulator Test (New Style) 187
Checking The Alternator (Early Models) 189
Parts Identification (New Style) 191
Disassembly And Assembly (New Style) 191
Stator Continuity Test 191
Stator Ground Test 191
Rotor Continuity Test 192
Rotor Ground Test 192
Rectifier Continuity (Diode) Test 192
Removing The Alternator (Early Models) 195
Repairing The Alternator (Early Models) 195
Installing The Alternator (Early Models) 196
STARTER (540) 197
Checking The Starter 197
Removing The Starter 197
Repairing The Starter 197
STARTER (543) 198
Checking The Starter 198
Removing The Starter 198
Repairing The Starter 199
Installing The Starter 202
ENGINE SERVICE 203
ENGINE SERVICE (540) KOHLER 205
TROUBLESHOOTING 207
CHECKS AND ADJUSTMENTS FOR THE ENGINE 209
Engine Oil Pressure 209
Valve Clearance 209
Compression 210
Throttle And Governor Linkage 210
Ignition System 211
Spark Plugs 211
CARBURETOR & FUELSHUT–OFF SOLENOID 212
Removing The Carburetor 212
Disassembly And Inspection Of The Carburetor 212
Assembly Of The Carburetor 212
Fuel Shut–off Solenoid 213
Non–Metallic Bodied Fuel Pumps 213
GOVERNOR 213
Removing The Governor 213
Installing The Governor 213
ENGINE AND HEAT SHIELD 214
Removing The Engine 214
Installing The Engine 215
Removing The Heat Shield 216
Installing The Heat Shield 216
RECONDITIONING THEVALVES 217
Repair Of The Valves And Guides 217
TIMING COVER, TIMING GEARS AND CAMSHAFT 218
Timing Cover 218
Timing Gears 218
Camshaft And Tappets 218
OIL PUMP AND RELIEF VALVE 218
Relief Valve 218
Oil Pump 219
Adjusting Gear Clearance For The Oil Pump 219
PISTONS, RODS AND CRANKSHAFT 220
Removing Pistons, Rods And Crankshaft 220
Crankshaft Bearing And End Play 220
CYLINDER HEAD 221
INTAKE AND EXHAUST MANIFOLD 222
FLYWHEEL 222
ENGINE SERVICE (543 & 543B) KUBOTA 223
TROUBLESHOOTING 225
FUEL SYSTEM 227
Replacing The Fuel Filter 227
To Remove The Air From The Fuel System 227
Fuel Injection Pump 228
Checking The Injection Pump 228
Installation 231
Timing The Fuel Injection Pump 231
Fuel Injector Nozzles 232
Removal 232
Checking The Fuel Injector Nozzles 233
Installation 235
Checking Glow Plugs 235
ENGINE AND ATTACHING PARTS 235
Removing The Engine 235
Installing The Engine 239
Engine Muffler 240
Engine Radiator Removal 241
Engine Radiator Installation 243
Engine Blower Housing Removal 244
Engine Blower Housing Installation 245
Engine Blower Fan And Flywheel Removal 245
Engine Blower Fan And Flywheel Installation 245
CYLINDER HEAD 246
Removing The Cylinder Head 246
Disassembly Of The Cylinder Head 247
Servicing The Cylinder Head 247
Assembly Of The Cylinder Head 249
Installing The Cylinder Head 249
Adjusting the Compression Release Mechanism 250
REPAIRING THE ENGINE 251
Removing The Gear Case 251
Removing The Timing Gear, Camshaft & Oil Pump 252
Removing Pistons And Crankshaft 253
Servicing The Timing Gear And The Camshaft 254
Servicing The Connecting Rods And Pistons 255
Servicing The Crankshaft 256
Servicing The Cylinder Liners 257
Servicing The Oil Pump 258
Servicing The Water Pump 259
ASSEMBLY OF THE ENGINE 259
Installing The Crankshaft 259
Installing The Pistons 259
Installing The Camshaft And Timing Gears 260
Installing The Gear Case Cover 261
TECHNICAL DATA 263
(540) KOHLER LOADER SPECIFICATIONS 265
Operation & Performance 265
Engine 265
Loader Hydraulics 266
Electrical 266
Drive System 266
Capacities 266
Tires 266
ENGINE SPECIFICATIONS – 540 LOADER (KOHLER) 267
Engine (General) 267
Cylinder Bore 267
Crankshaft 267
Camshaft 267
Connecting Rod 267
Piston, Pin And Rings 267
Valves, Guides & Tappets 268
Engine Torque 268
543 & 543B KUBOTA LOADER SPECIFICATIONS 269
Operation & Performance 269
Engine 269
Loader Hydraulics 270
Electrical 270
Drive System 270
Capacities 270
Tires 270
ENGINE SPECIFICATIONS – 543-543B LOADER 271
Fuel Injector Nozzles 271
Fuel Injection Pump 271
Cylinder Head 271
Valves 271
Valve Springs 271
Rocker Arms 271
Camshaft 271
Cylinders 272
Piston Rings 272
Piston 272
Crankshaft 272
Oil Pump 272
Thermostat 272
Engine Torque 273
Grinding Specifications for the Crankshaft 274
TORQUE SPECIFICATIONS 275
Engine Group – 540 Loader 275
Engine Group – 543 Loader 276
Fuel System Group 278
Steering Levers & Panel Group 279
Bob–Tach & Lift Arm Group 280
Seat Bar & Pedal Group 281
Brake, Chaincase & Axle Group 282
Hydraulic Group 283
Operator Cab, Main Frame & Rear Door Group 284
Hydrostatic Group–540 Loader 285
Hydrostatic Group–543 Loader 286
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 287
Hydraulic/Hydrostatic Fluid 287
DECIMAL AND MILLIMETER EQUIVALENTS 288
U S TO METRIC CONVERSION 288
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 289
SERVICE MANUAL REVISIONS 291
540–3 291
540–4 293
540–5 295
540–6 297
540–7 299
540–8 301
540–9 303
540–11 305
540–13 307
540–14 309
540–15 311
540–16 313
540–17 315
540–1 Thru 540–17 317
540–18 319
540–19 321
540-20 323

DESCRIPTION:

Bobcat 540 543 543B Loader Service Manual 6566532 (6-12) – PDF DOWNLOAD

540 (S/N 501012001 & Above)
543 (S/N 502412001 & Above)
543B (S/N 511111001 & Above)

FOREWORD:

This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS:

The following publications provide information on the safe use and maintenance of the loader and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.
• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routin e
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
• The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the
operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your
Bobcat dealer for more information on translated versions.
• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and
repair work.
• The Skid–Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish version.
• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

IMAGES PREVIEW OF THE MANUAL:

Customer Support: [email protected]

PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
• The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
• Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer

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