Bobcat 542B Loader Service Manual 6570791 (6-12) – PDF DOWNLOAD

Description

Bobcat 542B Loader Service Manual 6570791 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 542B Loader Service Manual 6570791 (6-12) – PDF DOWNLOAD

Language : English
Pages : 216
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 542B Loader Service Manual 6570791 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
SERIAL NUMBER LOCATIONS 9
Loader Serial Number 9
Engine Serial Number 9
DELIVERY REPORT 9
BOBCAT LOADER IDENTIFICATION 10
PREVENTIVE MAINTENANCE 11
SERVICE SCHEDULE 13
PREVENTIVE MAINTENANCE 14
LIFTING AND BLOCKING THE LOADER 14
Procedure 14
LIFT ARM STOP 15
Procedure 15
TRANSPORTING THE BOBCAT LOADER 15
Procedure 15
OPERATOR CAB 16
Operator Cab Fasteners 16
Raising And Lowering The Operator Cab 16
SEAT BAR SYSTEM 17
Seat Bar Description 17
Seat Bar Inspection 17
Seat Bar Maintenance 17
USING AN EXTRA BATTERY (JUMP STARTING) 18
Procedure 18
AIR CLEANER 19
Replacement Of Filter Element 19
FUEL SYSTEM 20
Filling The Fuel Tank 20
Fuel Filter 20
ENGINE LUBRICATION SYSTEM 21
Checking Engine Oil 21
Replacement Of Engine Oil And Filter 21
COOLING SYSTEM 22
Rear Grill 22
Coolant Level 23
Removing Coolant From The Cooling System 23
HYDRAULIC / HYDROSTATIC SYSTEM 24
Checking And Adding Fluid 24
Replacement Of The Hydraulic Filter Element 24
Removing The Hydraulic Fluid 25
FINAL DRIVE TRANSMISSION (CHAINCASE) 26
Checking Oil Level 26
TIRE MAINTENANCE 26
Wheel Nuts 26
Tire Rotation 26
Tire Inflation 26
LUBRICATION OF THE LOADER 27
Procedure 27
REMOTE START SWITCH 28
Procedure 28
HYDRAULIC SYSTEM 29
HYDRAULIC / HYDROSTATIC SCHEMATICS 31
TROUBLESHOOTING 37
HYDRAULIC SYSTEM INFORMATION 38
Flare Connections 38
Straight Thread O-Ring Fitting 38
Tubelines And Hoses 38
LIFT CYLINDER 39
Checking The Lift Cylinder(s) 39
Removal And Installation 39
TILT CYLINDER 41
Checking The Tilt Cylinder 41
Removal And Installation 41
Rod End Seal 42
HYDRAULIC CONTROL VALVE 43
Checking The Main Relief Valve With Auxiliary Couplers (Opt ) 43
Checking The Main Relief Valve Without Auxiliary Hydraulics 44
Main Relief Valve Removal And Installation 45
Adjusting The Main Relief Valve 45
Removal And Installation 46
HYDRAULIC PUMP 48
Checking The Output Of The Hydraulic Pump 48
Removal And Installation 49
PORT BLOCK 50
Removal And Installation 50
Charge By-Pass Valve 50
FILTER BY-PASS VALVE 52
Removal And Installation 52
HYDRAULIC FLUID RESERVOIR 53
Removal And Installation 53
HYDRAULIC CONTROL PEDALS 54
Removal And Installation 54
Adjustment 54
PEDAL LOCK LINKAGE 55
Installation 55
Adjustment 55
HYDROSTATIC SYSTEM 57
TROUBLESHOOTING 59
HYDROSTATIC SYSTEM INFORMATION 60
High Pressure Relief/Rreplenishing Valve Function 60
FRONT PANEL 61
Removal And Installation 61
STEERING LEVERS 63
Removal And Installation 63
Repairing The Steering Levers 64
STEERING LINKAGE 65
Steering Linkage Adjustment 65
Removal And Installation 66
Repairing The Pintle Lever 67
HYDROSTATIC MOTOR 69
Removal And Installation 69
Start-Up Procedure 70
HYDROSTATIC PUMP 71
Checking The Charge Pressure 71
Checking High Pressure Relief/Replenishing Valves 72
Removal And Installation 73
High Pressure Hose Routing 75
Start-Up Procedure 75
TOWING THE LOADER 76
Procedure 76
DRIVE SYSTEM 77
PARKING BRAKE 79
Adjustment 79
Removal And Installation 79
Block And Pucks 80
AXLES, SEALS AND BEARINGS 82
Removal 82
Installation 83
FINAL DRIVE CHAIN 86
Removal 86
Installation 86
CHAINCASE FLUID 87
Replacing The Chaincase Fluid 87
MAIN FRAME 89
OPERATOR CAB 91
Removal And Installation 91
OPERATOR CAB GAS CYLINDER 94
Removal And Installation 94
REAR DOOR 95
Door Latch Adjustment 95
Removal And Installation 96
LIFT ARMS 97
Removal And Installation 97
BOB-TACH 99
Removal And Installation 99
Tilt Cylinder Rod End Seal 100
Bob-Tach Wedges 101
FUEL TANK 103
Removal And Installation 103
ELECTRICAL SYSTEM 105
ELECTRICAL SCHEMATICS 108
ELECTRICAL SYSTEM INFORMATION 119
Description 119
TROUBLESHOOTING 119
BATTERY 120
Checking The Battery 120
Removal And Installation 120
ALTERNATOR 121
Checking The Alternator Output 121
Checking The Alternator Regulator 121
Removal And Installation 122
Disassenbly And Assembly 123
Checking Rotor, Stator And Rectifier 123
STARTER 126
Checking The Starter 126
Removal And Installation 126
Disassembly And Assembly 127
Cleaning And Inspection 128
Replacing The Brushes 128
ENGINE SERVICE 129
TROUBLESHOOTING 131
VALVE CLEARANCE 132
Adjustment 132
BELT SHIELD 133
Removal And Installation 133
FUEL LIFT PUMP 135
Checking 135
Removal And Installation 135
CARBURETOR 136
Description 136
Operation 136
Removal And Installation 138
Disassembly And Assembly 140
Inspection 140
IGNITION SYSTEM 141
Description 141
Troubleshooting 142
Ignition Timing Procedure 143
DISTRIBUTOR 144
Removal And Installation 144
Disassembly And Assembly 145
Checking The Distibutor 145
Spark Advance Test 145
IGNITION – DISTRIBUTORLESS 146
Description 146
Engine, Speed, Load & Temperature 146
Service Adjustments And Checks 147
Coil Removal And Installation 147
Engine Speed Sensor 148
Engine Coolant Temperature Sensor 148
GOVENOR 150
Belt Adjustment 150
Govenor Oil Level 150
Removal And Installation 150
Adjusting The Govenor 151
ENGINE MUFFLER 153
Removal And Installation 153
RADIATOR 155
Removal And Installation 155
ENGINE 157
Removal And Installation 157
OIL COOLER AND BLOWER HOUSING 160
Removal And Installation 160
FLYWHEEL AND U-JOINT 163
Removal And Installation 163
Flywheel Ring Gear 164
ROCKER ARMS 165
Removal And Installation 165
Disassembly And Assembly 165
Inspection 165
CYLINDER HEAD 165
Removal And Installation 165
Cleaning 166
Inspection 166
VALVES, VALVE GUIDES & SPRINGS 167
Removal 167
Valve Guides 167
Reconditioning The Valve And Valve Seat 168
Valve Springs 168
PISTON AND CONNECTING ROD 169
Removal And Installation 169
Fitting Pistons 169
Piston Rings 170
Piston Pin 170
Connecting Rods 170
CYLINDER BLOCK 171
Cleaning 171
Inspection 171
Refinishing Cylinder Bores 171
CRANKSHAFT FRONT OIL SEAL 171
Removal 171
Installation 171
CRANKSHAFT REAR OIL SEAL 172
Removal 172
Installation 172
CRANKSHAFT AND MAIN BEARINGS 172
Inspection 172
Refinishing Crankshaft Journals 173
Fitting Bearing with Plastigage 173
Crankshaft End Play 174
TIMING CHAIN COVER 174
Removal And Installation 174
TIMING CHAIN AND SPROCKETS 174
Removal 174
Inspection 174
Installation 175
CAMSHAFT 175
Checking Camshaft Lobe Lift 175
Removal And Installation 176
Inspection 176
Camshaft Bearing 176
Camshaft End Play 176
PUCH RODS AND TAPPETS 177
Inspecting The Push Rods 177
Inspecting The Tappet 177
OIL PAN 177
Removal 177
Cleaning And Inspection 177
Installation 177
OIL PUMP 178
Disassembly 178
Inspection 178
Assembly 178
TECHNICAL DATA 179
LOADER/ENGINE SPECIFICATIONS (S/N 11999 & BELOW) 181
SPECIFICATIONS 183
OPERATION AND PERFORMANCE 183
ENGINE 183
ELECTRICAL 184
DRIVE SYSTEM 184
HYDRAULIC SYSTEM 184
CAPACITIES 184
TIRES 184
ENGINE SPECIFICATIONS (S/N 11999 & BELOW) 185
Cylinder Block 185
Crankshaft 185
Connecting Rod 185
Pistons 185
Piston Pins 185
Piston Rings 185
Cylinder Head 186
Valves 186
Valve Springs 186
Tappets 186
Rocker Arms & Shaft 186
Oil Pump 186
Camshaft 187
Ignition System – Solid State 187
Distributor Advance 187
Belt Tension 187
Fuel Pump 187
Engine Torque 188
LOADER TORQUES 189
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 190
DECIMAL AND MILLIMETER EQUIVALENTS 191
U S TO METRIC CONVERSION 191
STANDARD TORQUE SPECIFICATIONS FOR BOLTS 192
LOADER/ENGINE SPECIFICATIONS (S/N 12001 & ABOVE) 193
SPECIFICATIONS 195
OPERATION AND PERFORMANCE 195
ENGINE 195
HYDRAULIC SYSTEM 196
ELECTRICAL 196
DRIVE SYSTEM 196
CAPACITIES 196
TIRES 196
ENGINE SPECIFICATIONS 197
Cylinder Block 197
Crankshaft 197
Connecting Rod 197
Pistons 197
Piston Pins 197
Piston Rings 197
Cylinder Head 198
Valves 198
Valve Springs 198
Tappets 198
Rocker Arms & Shaft 198
Oil Pump 198
Camshaft 199
Ignition System – Distributorless 199
Belt Tension 199
Fuel Pump 199
Engine Torque 200
SERVICE MANUAL REVISIONS 201
542B-1 201
542B-2 203
542B-3 205
542B-4 207
542B-5 209
542B-6 211
542B-7 213
542B-8 215

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