Bobcat 540 543 Loader Service Manual 6566181 (6-12) - PDF DOWNLOAD

5 4 0

Service Manual

540 (S/N 501011999 & Below) 543 (S/N 501111999 & Below)

6566181 (6-12) 1 of 256

Printed in U.S.A.

Dealer Copy -- Not for Resale

5 4 3

Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand Company and Bobcat Company or the products of either.

© Melroe Company 1981

2 of 256

Dealer Copy -- Not for Resale

MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in th e manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.

CORRECT

CORRECT

CORRECT

B-10731a

B-12365

B-7469

Never service the Bobcat SkidSteer Loader without instructions.

Use the correct procedure to lift or lower operator cab.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-11799

B-15231

B-15280

Have good ventilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by a n approved lift arm support device.

Replace it if damaged.

Never work on l oader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged.

Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

WRONG

WRONG

B-6590

B-6580 B-16102

B-6589 B-16102

Stop, cool and clean engine of flammable materials before checking fluids.

Never service or adjust loader with the engine running unless instructed to do so in the manual.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It c an penetrate the skin or eyes.

Never fill f uel tank with engine running, while smoking or when near open flame.

Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used.

Use eye protection approved for type of welding.

Keep rear door closed except for service. Close and latch door before operating the loader.

Lead-acid batteries produce flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on con tact.

Wear protective clothing. If a cid contacts body, flush well wit h water. For eye contact flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & M aintenance Manual can be perform ed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer.

3 of 256

MSW01-0805

Dealer Copy -- Not for Resale

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

4 of 256

Dealer Copy -- Not for Resale

FOREWORD This Service Manual gives the instructions for correctservicing, adjustment and overhauling of the Bobcat loader Hydraulic/Hydrostatic System, Drive System, Main Frame, Electrical System and Engine Service.

Make reference to the Operator ’s Manual for operating instructions (Starting, Daily Checks, Loader Operation, etc.).

PREVENTIVE MAINTENANCE

HYDRAULIC SYSTEM

A general inspection of the following items must be made when the Bobcat loader has had service or repair.

1. Check hydraulic/hydrostatic fluid level, engine oil level and fuel supply.

2. Inspect for any sign of fuel, oil or hydraulic fluid leaks.

HYDROSTATIC SYSTEM

3. Lubricate the loader.

4. Check the condition of the battery(ies) and the cables.

5. Inspect the air cleaner system for damage or leaks.

DRIVE SYSTEM

6. Check the warning lights to see if they light.

8. Check the Bob–Tach for wear and see if the wedges are damaged.

9. Check the safety items for condition (Operator Guard, Seat Belt, Seat Bar, Safety Signs (Decals), Safety Treads, etc.).

10. Make an inspection for loose or broken parts or connections.

MAIN FRAME

ELECTRICAL SYSTEM

11. Operate the loader, checking all functions.

Check the above items. If any are in need of repair or adjustment, contact the owner.

ENGINE SERVICE

Dealer Copy -- Not for Resale

7. Check the tires for wear and pressure.

TECHNICAL DATA

CONTENTS ALPHABETICAL ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. . . . INDEX DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. . . .

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. . . .

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. . . .

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. . . .

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. . .

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. . . .

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. . .

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. . . .

5 of 256

–3

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 6 of 256

–2

540, 543 Loader Service Manual

SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

W–2003–0797

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 tothe 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 is sold. it 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

Dealer Copy -- Not for Resale

operator. The Handbook is available from your dealer in an English edition or one of many other languages. See yo ur 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.

Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

This notice identifies procedures which must be followed to avoid damage to the machine.

I–2019–0284

W–2044–1285

Safety Alert Symbol: This symbol with a warning statement, means: “W arning, be alert! Your safety is involved!” Carefully read the message that follows.

SI05–0498 7 of 256 Revised Oct. 98

–5

540, 543 Loader Service Manual

SAFETY INSTRUCTIONS (Cont’d) • Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader . Safety glasses, hearing protection or loader special applications kit are required for some work. See your dealer for Melroe Safety equipmen t.

• Know where fire extinguisher and first aid kit are located and how to use them.

• Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosiv e dust or gases.

• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazard and overheating.

• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace an y damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to chec k for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuelorf cleaning parts. Use commercial nonflammable solvents.

• Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or anti–freeze.

• Do not use ether or starting fluids on engines which have glow plugs. These starting aids can cause explosion and inju re • Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or weldin g painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.

• Stop the engine and let it cool before adding fuel. No smoking!

• Use the procedure in the Operation & Maintenance or Service Manuals for connecting the battery.

A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].

A

P–3705

SI06–0398 8 of 256 Revised Oct. 98

–4

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

you or bystanders.

PREVENTIVE MAINTENANCE Page Number 1–8 1–4 1–13 1–11 1–1 1–14 1–16 1–14 1–3 1–13 1–16

1–10

1–15

Dealer Copy -- Not for Resale

ELECTRICAL SYSTEM . . . . . . . . . . . . . . .

ENGINE SERVICE . . . . . . . . . . . . . . . . . . .

FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC/HYDROSTATIC SYSTEM .

INTRODUCTION . . . . . . . . . . . . . . . . . . . . .

OPERATOR GUARD . . . . . . . . . . . . . . . . .

LIFT ARM STOP . . . . . . . . . . . . . . . . . . . . .

LUBRICATION OF THE LOADER . . . . . .

SERVICE SCHEDULE . . . . . . . . . . . . . . . .

SPARK ARRESTOR MUFFLER . . . . . . . .

STOPPING THE BOBCAT LOADER . . . .

TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . .

Paragraph Number 1–4 1–3 1–6 1–5 1–1 1–8 1–11 1–9 1–2 1–7 1–12

PREVENTIVE MAINTENANCE

WARNING

9 of 256

DO NOT service the Bobcat loader without instructions or taking the necessary safety precautions.

Before working on the loader , see the warnings and instructions at the beginning of this Service Manual.

After making the repair or adjustment, always check the function of the loader . Failure to obey warnings may cause injury or death.

–1––1–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 10 of 256

–1–0–

540, 543 Loader Service Manual

1 PREVENTIVE MAINTENANCE 1–1 INTRODUCTION The Preventive Maintenance Section of this Service Manual gives general maintenance procedures for the Bobcat loader. The other sections of the Service Manual will give the detailed description needed for disassembly and assembly and when replacement parts are needed.

Loader Serial Number B–05102

Fig. 1–1 Loader Serial Number

Engine Serial Number

B–02882

Fig. 1–2 Engine Serial Number (540)

1–1.1 Serial Number Identification

1–1.2 Loader Serial Number The Bobcat loader serial number plate location is on the inside of the left upright, above the grill (Fig. 1–1).

Loader Serial Number

B–02912

Fig. 1–3 Engine Serial Number (543)

Explanation of the Serial Number: XXXX

M

Dealer Copy -- Not for Resale

It is important to make correct reference to the Serial Number of the Bobcat loader and/or engine when making repairs or ordering parts. It is possible that the present loaders do not use all the same parts as the earlier loaders. It is possible that different procedures are used for service repair.

XXXX Production Sequence (Series) Plant Location Model, Engine Version

1–1.3 Engine Serial Number The engine serial number for the 540 Bobcat loader is located on the blower housing at the right side of the engine (Fig. 1–2).

The engine serial number for the 543 Bobcat loader is located at the left side of the engine above the fuel injection pump (Fig. 1–3).

1–1.4 Pre–Delivery Inspection (Fig. 1–4).

The Pre–Delivery Inspection must be completed when the new Bobcat gets to the dealer and before it is delivered to the customer.

The purpose of the Pre–Delivery Inspection is: 1. To see if the Bobcat loader is in correct operating condition at the time of the delivery.

11 of 256

–1–1–

Fig. 1–4 Pre–Delivery Inspection Form 540, 543 Loader Service Manual

2. To let the factory know when something is wrong with the Bobcat loader so that the problem can be corrected and prevented in the future.

All items on the inspection form must be completed according to the specifications in this manual.

One copy of the completed form is to be mailed to: CLARK EQUIPMENT MELROE DIVISION QUALITY CONTROL DEPT. GWINNER, ND 58040

Dealer Copy -- Not for Resale

The other copy is for the dealer records.

1–1.5 Thirty Hour Inspection (Fig. 1–5) The 30 Hour Inspection must be completed after the first 30 hours of loader operation.

The purpose of the 30 Hour Inspection is: 1. For adjustment and inspection after the first work period.

2. To correct wrong maintenance and operation methods.

3. For demonstrating correct service procedure to the customer.

All the items on the 30 Hour Inspection must be completed. The form must done be by the serviceman (mechanic), according to specifications in this manual.

When the 30 Hour Inspection has been completed, the form must be signed by (1) the serviceman (mechanic) that completed the inspection; (2) the Dealer; and (3) the owner/operator.

One copy of the completed form is to be mailed to: CLARK EQUIPMENT MELROE DIVISION SERVICE DEPT. GWINNER, ND 58040 One copy is for the owner/operator and one copy for the Dealer ’s records.

Fig. 1–5 30 Hour Inspection 12 of 256

–1–2–

540, 543 Loader Service Manual

1–2 SERVICE SCHEDULE

Maintenance work must be done at regular intervals. Failure to do so will result in damage to the Bobcat loader or the engine. The service schedule is a guide for correct maintenance of the Bobcat loader. DO NOT change this service schedule unless the frequency of service is increased when the Bobcat loader is operated in very hot, cold, dusty or corrosive conditions.

MODEL 540

543

DO NOT work on the loader with the lift arms in a raised position without support. Use lift arm stops or other methods.

SERVICE SCHEDULE ITEM

SERVICE REQUIRED

HOURS 8–10 50 100 250 500 1000

Check the condition indicator. Make inspection of the air cleaner system. Replace the element when the red ring shows in the indicator window.

Engine Oil Check level and add oil as needed.

Engine Cooling System Check and clean as needed (Including oil cooler grill).

Engine Coolant System Check the coolant level and add as needed. Remove any debris from the radiator grill area.

Tires Check for damage and check the tire pressure.

Operator Guard, Seat Belt & Check the operator guard fastening bolts to make Seat Bar sure they are tight. Check the condition of the seat belt. Check the seat bar for correct operation.

Safety Signs (Decals) Check for damaged decals. Replace any decals that are not there.

Pivot Points Add lubricant to all fittings.

Hydraulic/Hydrostatic Fluid Check the fluid level and add the recommended fluid as needed (See Section 8 for correct fluid).

Engine Oil and Filter Change, fill with new clean oil according to oil specification chart & install new filter.

Battery Check the battery cables & the battery water level.

Control Pedals and Steering Check both for correct operation. Make repairs & adjustments as needed.

Levers Check locking levers and wedges for condition and Bob–Tach operation.

Check operation. Make adjustment as needed.

Brakes Chaincase Fluid Check level. Add fluid as needed.

Hydraulic/Hydrostatic Filter Replace the filter element.

Spark Arrestor Muffler Remove the plug and clean the spark chamber.

Check the points & timing. Replace the spark plugs.

Engine Ignition System Engine Cylinder Head Bolts Tighten to correct torque after first 100 hours of loader operation. Adjust valve tappets.

Remove and clean housing and cooling fins.

Engine Air Housing Engine Air Cleaner System Check system for leaks. Replace element as needed.

Check oil level at check plug.

Injection Pump Oil Replace element or clean as needed.

Engine Fuel Filter Injection Pump Oil Replace the oil in the injection pump reservoir.

Seat Bar Lubricate the detent mechanism.

Steering Levers Add grease to the pivot bearings.

Replace the fluid.

Chaincase Replace the fluid. Clean the inlet screen and vent.

Hydraulic/Hydrostatic System

13 of 256

–1–3–

Dealer Copy -- Not for Resale

Engine Air Cleaner

540, 543 Loader Service Manual

1–3 ENGINE SERVICE (General)

Stop, cool and clean the engine of flammable material. Never service or adjust machine with the engine running unless instructed to do so.

B–03757

Fig. 1–6 Opening Door Latch

B–03853

Fig. 1–7 Opening Rear Door

Safety Latch

Dealer Copy -- Not for Resale

Open the rear door to service the engine. Pull the door latch up (Fig. 1–6) and turn to the left to release the door latch (Fig. 1–7). The door can then be fully opened to get to the engine. Push down on the door stop to hold the door open (Fig. 1–8), if so equipped. See Section 5 for theDoor Latch Adjustment.

Released

Locked Keep the rear door closed except for service. Make sure you close the door and fasten the latch tightly before operating the Bobcat loader.

B–03006

Fig. 1–8 Safety Latch

B–02229

Fig. 1–9 Removing Air Cleaner Element

1–3.1 Air Cleaner Service It is important to service the air cleaner at regular intervals for good engine performance and longservice life.

Element Dust Cap

Service the air cleaner as follows (Fig. 1–9):

1

1. Remove the dust cap and clean every day.

2. Make replacement of the element only when it becomes necessary.

C–01024

Fig. 1–10 Air Cleaner Assembly 14 of 256

–1–4–

540, 543 Loader Service Manual

3. Clean the inside of the filter housing so that the element has a smooth surface to contact at the seal (Fig. 1–10, Item 1). Check the filter housing for holes for corrosion, especially if the Bobcat loader is used in fertilizer application.

1

4. Install the filter element and tighten the wing nut.

5. Install the dust cap and tighten the clamp.

6. Check the hoses and clamps are tight.

2

1–3.2 Fuel System

B–03994

Fig. 1–11 Fuel Fill Location (540)

Dealer Copy -- Not for Resale

WARNING

Never add fuel to the Bobcat loader when the engine is running or is hot.

NO SMOKING!

Use 85 octane regular gasoline in the engine of the 540 Bobcat loader.

Use number 2 diesel fuel in the engine of the 543 Bobcat loader . During very cold temperature conditions, number 1 fuel is recommended.

1

To add fuel to the tank (Fig. 1–11 & 1–12), use the following procedure: 1. Use a clean, approved safety container to add the fuel.

B–03854

2. The key switch must be in the “OFF” position and the engine cool.

3. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING (Fig. 1–13).

4. Use only clean fuel of correct specifications.

Fig. 1–12 Fuel Fill Locations (543)

WRONG

the

5. Tighten the cap (Fig. 1–11), Item 1 & 1–12, Item 1) on the fuel tank.

540 Bobcat Loader: There is a fuel filter (Fig. 1–11, Item 2) in the fuel line by the fuel shut–of f valve. The fuel filter must be replaced every 250 hours of loader operation.

See Section 7 for the correct replacement procedure.

15 of 256

B–03884

Fig. 1–13 Fuel Fill Warning –1–5–

540, 543 Loader Service Manual

543 Bobcat Loader: There is a fuel filter located on the left side of the engine. The fuel filter must be replaced every 250 hours of loader operation. See Section 7 for the correct replacement procedure.

1–3.3 Engine Lubrication System Check the oil level each day.

To check the oil level, stop the engine, open the rear door and remove the dipstick (Fig. 1–14 & 1–15).

B–05153

Fig. 1–14 Checking Engine Oil (540)

B–05108

Fig. 1–15 Checking Engine Oil (543)

Keep the oil level between the marks on the dipstick (Fig. 1–16). DO NOT fill above the top mark. Use a good quality motor oil that meets API Service Classification (See Chart Below).

1–3.4 Replacement of the Engine Oil and Filter

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE)

Dealer Copy -- Not for Resale

Replace the engine oil and filter every 50 hours of loader operation.

Keep Oil Level Between These Marks

A–01528

Fig. 1–16 Engine Dipstick

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (GASOLINE: USE API CLASSIFICATION SF) (DIESEL: USE API CLASSIFICATION CD)

Crankcase Drain

To replace the engine oil and filter, use the following procedure: 1. Run the engine until it is at operating temperature. Stop the engine. Open the rear door.

2. Remove the drain plug (540–Fig. 1–17) (543–Fig. 1–19, Item 1).

16 of 256

Revised Apr. 94

–1–6–

B–05159

Fig. 1–17 Oil Drain (540) 540, 543 Loader Service Manual

3. Remove the oil filter (540–Fig. 1–18) (543–Fig. 1–19, Item 2).

4. Clean the filter housing surface.

2

5. Install the drain plug. Remove the oil fill cap (540–Fig. 1–14) (543–Fig. 1–19, Item 3). Add the correct amount of oil to the engine (See the Oil Chart for the correct oil).

B–02225

Fig. 1–18 Oil Filter (540)

1

1–3.5 Engine Cooling System 540 Bobcat Loader: The oil cooler grill and engine cylinder cooling fins must be kept clean and free of debris or overheating of the engine will result.

WARNING

3

B–05110

Fig. 1–19 Engine Service (543)

Use safetty goggles when using air pressure to clean the grill area. DO NOT use cold water on a hot engine.

Dealer Copy -- Not for Resale

6. Start the engine and let it runfor several minutes. Stop the engine. Check the oil level. Add oil if the level is not at the top mark on the dipstick (Fig. 1–16).

Use air pressure or water to clean the oil cooler grill (Fig. 1–20).

Remove the shrouding on the engine to clean the cooling fins. Make sure to wear safety goggles when using air pressure or water spray for cleaning the fins.

Use a brush and scraper tool to remove the hard deposits on the cooling fins (Fig. 1–21). The oil cooler can be removed for better cleaning.

Make sure to replace all the covers and shrouding after cleaning the engine.

IMPORTANT

Never operate the engine with any of the covers or shrouding removed.

B–02216

Fig. 1–20 Cleaning Grill (540)

543 Bobcat Loader: The radiator grill area must be kept clean and free of debris or overheating of the engine will result.

Keep the blower fan clean and free from debris (Fig. 1–22, Item 1).

B–02230

Fig. 1–21 Cleaning Cooling Fins (540) 17 of 256

–1–7–

540, 543 Loader Service Manual

Check the coolant level every day at the coolant recovery tank (Fig. 1–22, Item 2). Correct level of the recovery tank is 1/3 full when the engine is cold and 2/3 full when the engine is warm.

2

Add coolant at the recovery tank only.

NOTE: Protect the cooling system from freezing temperatures by adding 50/50 ethylene glycol and water (Pre–Mixed) to the cooling system.

The cooling system must be drained and flushed clean at one year intervals. Fill with clean coolant that contains rust inhibitor.

1

1–4 ELECTRICAL SYSTEM 1–4.1 Electrical System Service 1. Check the battery cables and make sure they areclean and tight. Check the water level of the battery. Remove any acid or corrosion fromthe battery and cables with a sodium bicarbonate and water solution (Fig. 1–23). Cover the battery terminals and cables with grease.

Fig. 1–22 Coolant Recovery Tank (543)

2. Check the tension of the alternator belt (See Section 6 for the correct procedure).

Dealer Copy -- Not for Resale

3. Check all wires for being broken or open wires.

NOTE: The warning lights (on the dash panel) will come ON when the key switch is turned ON. When the engine is started, the warning lights must go OFF. If they do not, stop the engine and find the problem.

1–4.2 Using an Extra Battery (Booster Starting)

Keep arcs, sparks, flames and lighted tobacco away from batteries.

When jumping from booster battery make final connection (negative) at engine frame.

WARNING

Water and Baking Soda Solution

Do not jump start or charge a frozen or damaged battery. Warm battery to 60_F. (16_C) before connecting to a charger,. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging.

Battery gas can explode and cause serious injury.

A–02741

Fig. 1–23 Cleaning the Battery

W–2066–1296

If it is necessary to use an extra battery to start the engine, BE CAREFUL! This is a two–person operation. There must be one person in the operator’s seat and one person to connect and disconnect the battery cables.

18 of 256

Revised Oct. 98

–1–8–

540, 543 Loader Service Manual

Connects to Connects to the The Starter Engine for Ground Batteries contain acid which burns eyes and skin on contact.

Wear goggles, protective clothing and rubber gloves to keep acid off body.

2

In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water forat least 15 minutes.

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

W–2065–1296

Connects to the Engine for Ground

1

LOADER BATTERY Booster Cables

EXTRA BATTERY B–03711

Fig. 1–24 Connecting the Extra Battery

If it is necessary to use an extra battery to start the engine, BE CAREFUL! This is a two–person operation. There must be one person in the operator’s seat and one person to connect and disconnect the battery cables.

2. The battery to be used must be of the same voltage.

3. Battery terminals have identification marks. The positive terminal is marked (+) and the negative terminal is marked (–).

4. The negative terminal (–) of the battery must be connected to the engine.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

When jumping from booster battery make final connection (negative) at engine frame.

WARNING

Do not jump start or charge a frozen or damaged battery. Warm battery to 60_F. (16_C) before connecting to a charger,. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging.

Dealer Copy -- Not for Resale

1. The ignition must be in the off position.

Battery gas can explode and cause serious injury.

W–2066–1296 5. Connect the end of the first cable to the positive terminal (+) of the booster (Fig. 1–24, Item 1). Connect the other end of the same cable to the positive terminal (+) of the loader battery (Fig. 1–24, Item 2).

6. Connect the end of the second cable to the negative terminal (–) of the booster battery (Fig. 1–24, Item 3). Connect the other end of the second cable to the engine (Fig. 1–24, Item 4). DO NOT connect the cable directly to the negative terminal (–) of the loader battery . Connecting the cable directly to the battery can cause a spark and destroy the battery and cause personal injury.

7. Keep the cables away from the fans and belts.

NOTE: The operator must be in the operator ’s seat and have the seat belt fastened.

8. Start the engine.

9. After the engine has started, remove the cable connected to the engine (Fig. 1–24, Item 4).

10. Then remove the cable from the loader battery post positive terminal (+) (Fig. 1–24, Item 2).

19 of 256

Revised Oct. 98

–1–9–

540, 543 Loader Service Manual

Damage to the alternator will occur if: • The engine is operated with battery cables disconnected.

IMPORTANT

• The cables are connected when using a fast charger or when welding on the Bobcat loader (Remove both cables from the battery).

• The extra battery cables are connected wrong.

B–03709

Fig. 1–25 Removing Cable

1–4.3 Installing New Battery

Dealer Copy -- Not for Resale

NOTE: See Section 6 Paragraph 6–3.1 and 6–3.3 for more information on removing and replacing batteries.

1. Remove the negative battery cable from the battery first, using a cable puller (Fig.1–25).

Remember the position of the battery cables so you can connect the cables correctly when installing the battery.

2. Remove the battery holddown clamp (Fig. 1–26 or 1–27).

Remove the battery from the battery compartment.

3. Clean the terminal posts (Fig. 1–28) of the new battery and the ends on the battery cables.

4. Install the new battery in the battery compartment.

B–05159

B–05172

Fig. 1–26 Location of the Battery (540)

Fig. 1–27 Location of the Battery (543)

5. Install the holddown clamp (Fig. 1–26 or 1–27).

6. Install the positive battery cable first and tighten. Connect the negative cable last to prevent sparks.

B–03707

Fig. 1–28 Cleaning Battery Terminals 20 of 256 Revised Oct. 98

–1–10–

540, 543 Loader Service Manual

1–5 HYDRAULIC/HYDROSTATIC FLUID NOTE: For more information on the Hydraulic System see Section 2 and for more information on the Hydrostatic System see Section 3.

WARNING

Diesel fuel or hydraulic fluid under pressure can penetrate skin eyes, causing serious injury or death.

Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. W ear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

B–05156

Fig. 1–29 Filter Location (540)

W–2072–0496

1–5.1 Replacing the Hydraulic/Hydrostatic Filter The tools listed will be needed to do the following procedure: MEL–1183 Filter Wrench

Dealer Copy -- Not for Resale

Replace the hydraulic/hydrostatic filter every 100 hours of loader operation or as often as necessary.

To replace the hydraulic/hydrostatic filter, use the following procedure: 1. Stop the engine. Open the rear door.

B–05166

2. Clean the area around the filter housing.

Fig. 1–30 Filter Location (543)

3. Remove the filter element (Fig. 1–29 or 1–30) with a filter wrench.

4. Clean the surface of the filter housing head where the filter element seal contacts the filter housing.

5. Lubricate the rubber gasket with fluid.

6. Install the filter element and hand tighten only.

7. Operate the loader and check for leaks at the filter.

1–5.2 Checking and Adding Hydraulic/Hydrostatic Fluid

3

1. Put the loader on a level surface, lower the lift arms and tilt the Bob–T ach fully back. Stop the engine.

2. Open the bottom check valve on the side of the reservoir (Fig. 1–31, Item 1). The fluid level is good if the fluid level is between the top and bottom check valves. If no fluid flows, close the valve and proceed with step 3.

3. Open the top check valve (Fig. 1–31, Item 2). Remove the fill cap (Fig. 1–31, Item 3) from the reservoir. Add fluid to the reservoir until it flows from the top check valve. Close the valve and replace the fill cap (See Section 8 for the correct fluid specifications).

2 1 B–03927

Fig. 1–31 Checking/Adding Fluid 21 of 256

Revised Oct. 98

–1–11–

540, 543 Loader Service Manual

1–5.3 Removing the Hydraulic/Hydrostatic Fluid The hydraulic/hydrostatic fluid must be removed from the reservoir every 1000 hours of loader operation.

Replace the hydraulic/hydrostatic fluid more often if it becomes dirty or after any major repairs.

B–05163

1. To Remove the fluid from the reservoir, use the following procedure:

Fig. 1–32 Hose Clamp

B–05164

Fig. 1–33 Hose Fitting

(a) Open the rear door and remove the hose clamp (Fig. 1–32) from the rear door.

B–05178

(b) Remove the hose at the oil cooler fitting (Fig. 1–33).

Fig. 1–34 Removing Fluid

B–05144

Fig. 1–35 Hose Fitting

(c) Put the hose in a container and drain the hydraulic/hydrostatic reservoir (Fig. 1–34).

543 Bobcat Loader (a) Open the rear door and remove the hose at the oil cooler fitting (Fig. 1–35).

(b)

B–05143

Fig. 1–36 Hose Plug

Put plugs in the hose and the oil cooler (Fig. 1–36).

(c) Pull the hose between the hydraulic/hydrostatic filter and the main frame and down and out of the rear of the loader.

(d) Remove the plug, put the hose in a container (Fig. 1–37) and drain the hydraulic/hydrostatic reservoir.

B–05176

2. After all the fluid is removed from the reservoir, connect the hose.

22 of 256

–1–12–

Fig. 1–37 Removing Fluid 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

540 Bobcat Loader:

3. Remove the snap ring and remove the 100 mesh screen from the reservoir fill pipe (Fig. 1–38). Wash the screen in clean solvent and install it in the fill pipe.

4. Fill a new filter element (See Paragraph 1–5.1).

5. Add hydraulic/hydrostatic fluid to the reservoir (See Paragraph 1–5.2).

6. Operate the loader and the hydraulic controls. Stop the engine. Check the fluid level. Add fluid as needed.

1–6 FINAL DRIVE TRANSMISSION (Chaincase) The chaincase is filled with the same type of fluid as the hydraulic/hydrostatic reservoir for chain lubrication (See Section 8 for the correct fluid specification).

1–6.1 Checking Chaincase Fluid C–02602

1. Put the loader on a level surface. Stop the engine.

Fig. 1–38 100 Mesh Screen

2. Remove the plug (Fig. 1–39, Item 1) at the front of the chaincase housing.

Dealer Copy -- Not for Resale

3. Add fluid through the check plug hole until the fluid flows from the check plug hole.

4. Install the plug and tighten.

1–7 SPARK ARRESTOR MUFFLER

This loader is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler.

IMPORTANT

It is necessary to do maintenance on this spark arrestor muffler to keep it in working condition. The spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation.

If this machine is operated on flammable forest, brush or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442, PRC.

1 C–02037

Fig. 1–39 Chaincase Plug

Make reference to local laws and regulations for spark arrestor requirements.

1–7.1 Cleaning the Spark Arrestor Muffler 1. Stop the engine. Open the rear door.

23 of 256

–1–13–

540, 543 Loader Service Manual

2. Remove the plug(s) at the bottom of the muffler (540 – Fig. 1–40) (543 – Fig. 1–41).

Never use machine in atmosphere with explosive dust or gases or whereexhaust can contact flammable material. Failure to obey warnings can cause injury or death.

W–2068–1285 3. Start the engine. Hold a piece of wood over the exhaust outlet for about 10 seconds to force the exhaust gases through the muffler plug(s).

B–05169

Fig. 1–40 Muffler Plug Location (540)

Dealer Copy -- Not for Resale

4. Stop the engine. Install the plug(s) and tighten. Close the rear door.

1–8 OPERATOR GUARD The Bobcat loader has an operator guard (ROPS & FOPS) as standard equipment. The ROPS & FOPS protects the operator from rollover and falling objects.

Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Melroe Company. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

B–05168

Fig. 1–41 Muffler Plug Location (543)

C–02599

Fig. 1–42 Checking Guard Nuts

W–2069–1285

Always make sure the operator guard fastening bolts and nuts 1–42).

are tight (Fig.

NOTE: See Section 5 for Raising and Lowering the Operator Guard.

1–9 LUBRICATION OF THE LOADER 1–9.1 Lubrication of the Loader Lubricate the Bobcat loader as specified in the service Schedule on Page 1–3 for the best performance of the loader.

24 of 256

–1–14–

540, 543 Loader Service Manual

See figure 1–43 for the location ofthe grease fittings. Always use a good lithium based multi–purpose grease when you lubricate the Bobcat loader. Apply grease until the extra grease shows.

HYDRAULIC RESERVOIR

CHAIN CASE

Grease the pivot bearings (Fig. 1–44 & 1–45) every 500 hours of loader operation.

B–05191

1–10 TRANSPORTING THE BOBCAT LOADER 1–10.1 Loading the Bobcat Loader

Fig. 1–44 Lubrication of Pivot Bearing

COOLANT TRANSMISSION OIL FILTER

GREASE GREASE

6561387

Use steel loading ramps when loading the Bobcat loader onto a transport vehicle. DO NOT use wooden planks.

Fig. 1–43 Lubrication Chart

Dealer Copy -- Not for Resale

Steel ramps are available to be used to load the Bobcat loader onto a transport vehicle.

B–05197

Fig. 1–45 Lubrication of Pivot Bearing

A loader with an empty bucket or no attachment must be loaded backwards onto the transport vehicle (Fig. 1–46).

1–10.2 Fastening the Loader to the Transport Vehicle 1. Lower the bucket or attachment to the floor and stop the engine.

2. Engage the parking brake.

3. Install the chains to hold the Bobcat loader in position to prevent it from moving during sudden stops or when going up or down slopes.

B–02668R

Fig. 1–46 Loading the Bobcat Loader 25 of 256

–1–15–

540, 543 Loader Service Manual

4. Put a chain through the axle gusset and fasten to theBobcat loader and to the transport vehicle (Fig. 1–47).

5. Fasten the chains, one in each upright cutout, to the loader and to the transport vehicle (Fig. 1–48).

Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.

W–2059–0598

1. Two persons are needed to install or remove the lift arm stop. One person must be in the operator’s seat, with the seat belt fastened, and the second person is to install the lift arm stop.

C–02565R

Fig. 1–47 Installing Holddown Chains 2. Start the engine and raise the lift arms all the way up.

3. Have the second person install the lift arm stop over the rod of one of the lift cylinders (Fig. 1–49).

4. Make sure the lift arm stop is tight against the cylinder rod. Lower the lift arms until the stop is held between the lift arms and the lift cylinder.

5. Stop the engine.

WARNING

Service lift arm sipport device if damaged or if parts are missing.

Using a damaged lift arm support or with missing parts can cause lift arms to drop causing injury or death.

W–2271–1197

C–02563

1–12 STOPPING THE BOBCAT LOADER When you are stopping and leaving the procedure:

Fig. 1–48 Fastening the Loader Bobcat loader, use the following

1. Stop the Bobcat loader on level ground.

2. Lower the lift arms all the way down and put the edge of the bucket on the ground.

3. Pull the throttle all the way backward to decrease the engine RPM. T urn the key switch to the “OFF” position.

4. Engage the parking brake.

5. Lift the seat bar and disconnect the seat belt.

6. Make sure the hydraulic controls are in the locked position when the seat bar is raised.

7. Remove the key from the switch to prevent the operation of the Bobcat loader by personnel other than the approved operator.

26 of 256

Revised Oct. 98

–1–16–

6558015

Fig. 1–49 Lift Arm Stop 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

1–11 LIFT ARM STOP

HYDRAULIC SYSTEM Page Number

2–10 2–3

2–27 2–3

2–7 2–4 2–2 2–5 2–9 2–8 2–6 2–1

2–23 2–10 2–2 2–15 2–26 2–24 2–21 2–1

HYDRAULIC SYSTEM

Dealer Copy -- Not for Resale

CONTROL PEDAL, LINKAGE AND LOCKS . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC CONTROL VALVE . . . . . . .

HYDRAULIC/HYDROSTATIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC PUMP . . . . . . . . . . . . . . . . . .

HYDRAULIC SYSTEM INFORMATION .

LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . .

10 MICRON FILTER BY–PASS VALVE . .

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . .

TILT CYLINDER . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING . . . . . . . . . . . . . . . .

Paragraph Number

WARNING

27 of 256

DO NOT service the Bobcat loader without instructions or taking the necessary safety precautions.

Before working on the loader , see the warnings and instructions at the beginning of this Service Manual.

After making the repair or adjustment, always check the function of the loader . Failure to obey warnings may cause injury or death.

–2––1–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 28 of 256

–2–0–

540, 543 Loader Service Manual

29 of 256

Dealer Copy -- Not for Resale

30 of 256

Dealer Copy -- Not for Resale

31 of 256

Dealer Copy -- Not for Resale

32 of 256

Dealer Copy -- Not for Resale

33 of 256

Dealer Copy -- Not for Resale

34 of 256

Dealer Copy -- Not for Resale

35 of 256

Dealer Copy -- Not for Resale

36 of 256

Dealer Copy -- Not for Resale

37 of 256

Dealer Copy -- Not for Resale

38 of 256

Dealer Copy -- Not for Resale

2 HYDRAULIC SYSTEM 2–1 TROUBLESHOOTING The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

PROBLEM

CAUSE 1, 2, 3, 4

Slow hydraulic system action.

1, 3, 5, 6, 7

Hydraulic action is not smooth.

1, 5, 6, 7, 8

Lift arms go up slowly at full engine RPM.

1, 3, 5, 6, 7, 9, 11

The lift arms or Bob–Tach will move with the pedal in neutral position.

5, 10

The lift arms come down slowly with the pedal in the neutral position.

5, 10, 11, 12 Dealer Copy -- Not for Resale

The hydraulic system will not operate.

KEY TO CORRECT THE CAUSE 1. The fluid level is not correct.

2. The pedal linkage is disconnected 3. The hydraulic pump is not working correctly.

4. The relief valve is not working correctly.

5. The pedal linkage is not adjusted correctly.

6. Relief valve is not at the correct pressure.

7. Suction leak on the inlet side of the hydraulic pump.

8. Fluid is cold.

9. Using the loader for more than its rated capacity.

10. Spool in the valve section is not centering or the centering spring is broken.

11. Internal leak at the lift cylinder(s).

12. External leak at the lift cylinder(s).

39 of 256

–2–1–

540, 543 Loader Service Manual

2–2 HYDRAULIC SYSTEM INFORMATION

IMPORTANT

When making repairs on hydraulic system, keep all parts clean and remove all dirt from the area before you begin disassembly . Use caps and plugs to keep dirt out of tubelines and openings.

Mark a Line on Nut Flats of Both Nuts

Tighten to Correct Amount from Chart

2–2.1 37° Flare Connections Use the following procedure to tighten the flare fittings:

A–01897

1. Tighten the nut until it makes contact with the seat.

Fig. 2–1 Tightening Flare Fittings

2. Make a mark across the “flats” of both the male and female parts of the connection (Fig. 2–1).

FITTING THREAD SIZE

ROTATE NUMBER OF HEX FLATS

9/16–18

2

3/4–16

2

7/8–14

1 1/2–2

1–1/16–12

1

1–5/16–12

3/4–1

If the fitting leaks after tightening, disconnect it and inspect the damage. Replace as needed.

Dealer Copy -- Not for Resale

3. Use the chart below to find the correct tightness needed.

Nut

seat area for

Washer O–ring

2–2.2 Straight Thread O–ring Fitting When installing this fitting, the o–ring must be first lubricated with grease. Loosen the jam nut, turn the fitting into place and connect the tubeline, then tighten the jam nut.

Tighten the jam nut until it and the washer are tight against the surface (Fig. 2–2).

The O–ring must be pushed into the space as shown.

Nut Washer

2–2.3 Tubelines and Hoses

O–ring

Make replacement of tubelines which are bent or have become flat. There will be a restriction of fluid flow, which will make for slow hydraulic action and cause heat.

Make replacement of hoses which show signs of wear, damage or weather cracked rubber.

When installing tubelines or hoses, make sure you use two (2) wrenches when tightening them.

40 of 256

–2–2–

A–01852

Fig. 2–2 Straight Thread Seal 540, 543 Loader Service Manual

2–3 HYDRAULIC CONTROL VALVE

IMPORTANT

When making repairs on hydraulic system, clean the work area before disassembly and keep all parts clean. Always use caps and plus on hoses, tbelines and ports to keepdirt out. Dirt can quickly damage the system.

I–2056–0793

Wear in the control valve or spools will cause the hydraulic cylinders to move when the controls are in the neutral position. W ear can also cause loss of hydraulic power.

To find an internal leak in the control valve, first check the condition of the cylinders. If the lift arm or tilt cylinder still move or extend after the cylinders are checked to be good, then check the control valve for the following: 1. Spool not centering in the valve section when the pedal is released. The spring can be broken or check the pedal linkage and adjust it so it will keep the spool in the neutral position.

2. Check for leaks in the valve because of wear or cracked valve body.

WARNING

Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.

W–2059–0598

The tools listed will be needed to do the following procedure: MEL–1003 – Hydraulic Tester MEL–1006 – Hydraulic Test Kit

WARNING

Loader must be restrained for some service and repair. When balance of loader is changed by removal of lift arms or engine, or when it is necessary to rotate axles, jackstands should be put under both front axles and both rear corners of frame. Blocks by wheels can be climbed and do not stop loader.

Dealer Copy -- Not for Resale

2–3.1 Relief Valve

W–2310–0398

Checking the Relief Valve 1. Operate the loader until the fluid is at operating temperature.

2. Stop the engine.

3. Activate the auxiliary hydraulic control (right steering lever) to raise the hydraulic pressure.

41 of 256

Revised Oct. 98

–2–3–

540, 543 Loader Service Manual

3. Connect the hydraulic tester to the auxiliary quick couplers (Fig. 2–3).

IMPORTANT The hydraulic tester must be in the fully open position before you start the engine.

I–2024–0284

4. Start the engine and run it atidle RPM.

B–04058

Fig. 2–3 Checking the Relief Valve

5. Activate the auxiliary hydraulic control (right steering lever) to put pressure into the hydraulic tester (inlet port). Watch the flow on the hydraulic tester.

Increase the engine RPM to maximum.

Dealer Copy -- Not for Resale

6. Turn the restrictor control on the tester to increase the pressure.

7. Read the pressure gauge. The pressure must be 1575–1675 PSI (10859–11549 kPa).

Removal of the Relief Valve 1. Stop the engine.

2. Activate the hydraulic controls to release the hydraulic pressure.

3. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

4. Clean the control valve area.

B–05297

5. Remove the plug for the relief valve (Fig. 2–4).

Fig. 2–4 Removing the Relief Valve

6. You may have to use a magnet to remove the poppet from the control valve.

7. Clean and inspect the relief valves parts.

8. The shims (Fig. 2–5, Item 1) can be added or removed to get the correct pressure.

Installation of the Relief Valve 1. Install a new o–ring on the plug for the relief valve.

2. Install the seat, poppet, spring, shims and plug in the correct order (Fig. 2–5) or damage can occur to the hydraulic pump.

1

3. Check the hydraulic pressure again using the above procedure. If the pressure is not correct, add or remove the shims (Fig. 2–5, Item 1).

B–05313

Fig. 2–5 Relief Valve Assembly 42 of 256

Revised Oct. 98

–2–4–

540, 543 Loader Service Manual

4. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

5. Remove the hydraulic tester and the jackstands from under the loader frame.

2–3.2 Removal of the Hydraulic Control Valve

B–05340

Fig. 2–6 Removing Hose

B–05301

Fig. 2–7 Valve Tilt Linkage

B–05309

Fig. 2–8 Valve Auxiliary Linkage

Dealer Copy -- Not for Resale

Lift the loader and put jackstands under the frame so there is no danger of the loader falling and causing personal injury.

B–05302

Fig. 2–9 Auxiliary Linkage

The tools listed will be needed to do the following procedure: MEL–1074 – O–ring Seal Hook MEL–1190 – Magnet 1. Stop the engine.

2. Activate all the hydraulic controls to release the hydraulic pressure.

3. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

4. Remove the hydraulic/hydrostatic fluid from the reservoir (See Paragraph 1–5.3, Page 1–12).

5. Clean the area around the control valve. Always use caps or plugs when removing hoses or tubelines.

B–05300

Fig. 2–10 Valve Lift Linkage

6. Remove the hose from the control valve (Fig. 2–6) which goes to the port block.

7. Disconnect the tilt linkage from the control valve (Fig. 2–7).

8. Loosen the lock nut at the auxiliary control rod at the steering levers (Fig. 2–8) so the linkage can be turned when it is removed from the valve.

9. Remove the hair pin and pin at the auxiliary linkage at the control valve (Fig. 2–9) and remove the linkage from the control valve.

10. Disconnect the lift linkage at the control valve (Fig. 2–10).

11. Disconnect all the tubelines from the control valve (Fig. 2–11).

12. Remove the tire and wheel assembly at the right rear of the loader.

43 of 256

–2–5–

B–05259

Fig. 2–11 Disconnecting the Tubelines 540, 543 Loader Service Manual

13. Remove the two (2) bolts from the control valve (Fig. 2–12).

14. Remove the hydraulic control valve from the loader (Fig. 2–13).

2–3.3 Disassembly of Hydraulic Control Valve

the

B–05314

Fig. 2–12 Removing Valve Bolts

B–05298

Fig. 2–13 Removing the Control Valve

1. Clean the control valve before disassembly.

Mark each spool before disassembly so they will go back to their original bore.

B–05312

Fig. 2–14 Lift Section Orifice

B–05277

Fig. 2–15 Auxiliary End Cap

2. Remove the orifice from the lift section of the control valve (Fig. 2–14).

3. Put the control valve inthe vise.

4. Loosen the auxiliary section end cap (Fig. 2–15).

B–05275

Fig. 2–16 Auxiliary Spool

B–05268

Fig. 2–17 Lift End Cap

5. Remove the auxiliary section spool (Fig. 2–16).

6. Loosen the lift section end cap (Fig. 2–17).

7. Remove the lift section spool (Fig. 2–18).

8. Loosen the tilt section end cap (Fig. 2–19).

44 of 256

B–05276

Fig. 2–18 Lift Spool –2–6–

B–05278

Fig. 2–19 Tilt End Cap 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

IMPORTANT

9. Remove the tilt section spool (Fig. 2–20).

10. Remove the o–rings from the control valve (Fig. 2–21).

11. Loosen the end cap for therelief valve (Fig. 2–22).

B–05274

Fig. 2–20 Tilt Spool

B–05263

Fig. 2–21 Control Valve O–rings

13. Use a magnet and remove the relief valve poppet from the bore (Fig. 2–24).

B–05267

Fig. 2–22 Relief Valve End Cap

B–05266

Fig. 2–23 Relief Valve Spring

14. Use the special tool and remove the seat from the control valve (Fig. 2–25).

15. If the detent mechanism is not disassembled, remove the o–ring over the valve spool lands (Fig. 2–26).

B–05265

Fig. 2–24 Relief Valve Poppet

Dealer Copy -- Not for Resale

12. Remove the end cap and spring from the relief valve bore. Be careful not to lose any of the shims in the end cap (Fig. 2–23).

B–05264

Fig. 2–25 Relief Valve Seat

2–3.4 Detent Mechanism

NOTE: Only disassemble the detent mechanism if it is damaged or parts are broken.

45 of 256

B–05270

Fig. 2–26 O–ring on the Spool –2–7–

540, 543 Loader Service Manual

1. To disassemble the detent mechanism, wrap cloth around the end cap and valve spool (Fig. 2–27). Pull the end cap off the valve spool. Be careful not to lose the balls from the detent when removing the cloth from the spool.

2. Remove the end cap from the detent bolt. Using a punch, loosen the detent bolt (Fig. 2–28) through the hole in the detent bolt.

B–05287

Fig. 2–27 Removing End Cap from Spool

4. The detent bolt for the lift spool has an o–ring installed at the end of the detent bolt (Fig. 2–30). Install a new o–ring before installing the bolt.

B–05272

5. Install a new o–ring on the spool before assembling the detent mechanism.

Fig. 2–28 Detent Bolt

B–05286

Fig. 2–29 Detent Mechanism Assembly

6. When installing the detent spring and balls, use the following procedure: (a) Install the spring in the hole of the detent bolt. (b) Put grease on the ends of the spring and put the balls on the ends of the springs (Fig. 2–31).

B–05285

Fig. 2–30 Detent Bolt O–ring

B–05284

Fig. 2–31 Detent Spring and Ball

(c) Push the end cap over the balls until they seat inside the end cap (Fig. 2–32).

2–3.5 Assembling the Hydraulic Control Valve 1. If the detent mechanism was not removed, carefully install a new o–ring over the three (3) valve spools (Fig. 2–33).

46 of 256

B–05308

Fig. 2–32 Installing End Cap –2–8–

B–05270

Fig. 2–33 Installing the O–ring 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

3. Remove the dent bolt, spring and seat from the spool (Fig. 2–29).

2. Install new o–rings in the three (3) bores for the spools of the control valve (Fig. 2–34).

3. Carefully install all three (3) spools in their correct locations (Fig. 2–35).

B–05263

Fig. 2–34 Installing the O–rings

B–05274

Fig. 2–35 Installing Spools

5. Install the seat for the relief valve, using the special tool (Fig. 2–37) and tighten.

B–05277

Fig. 2–36 Tighten the End Caps

Dealer Copy -- Not for Resale

4. Tighten the end caps of the valve spools (Fig. 2–36).

B–05264

Fig. 2–37 Installing Relief Valve Seat

6. Install the poppet.

7. Install the spring and the end cap (Fig. 2–38). Make sure all the shims are in the end cap.

Tighten the end cap.

B–05266

Fig. 2–38 Installing Relief Valve

B–05312

Fig. 2–39 Installing the Orifice

8. Install the orifice in the lift section port of the control valve (Fig. 2–39).

9. Remove the plug (Fig. 2–40) and check the poppet and seat of the load check valves (Fig. 2–41). Replace parts as needed.

47 of 256

B–05294

Fig. 2–40 Load Check Plug –2–9–

B–05290

Fig. 2–41 Load Check Poppet 540, 543 Loader Service Manual

2–3.6 Installing the Hydraulic Control Valve 1. Install the control valve in the loader (Fig. 2–42).

2. Install the two (2) bolts in the control valve (Fig. 2–43) and tighten to 11–13 ft.–lbs. (15–18 Nm) torque.

3. Connect all the tubelines to the control valve (Fig. 2–44).

B–05298

Fig. 2–42 Installing the Control Valve

B–05314

Fig. 2–43 Installing the bolts

4. Connect the auxiliary linkage at the steering lever (Fig. 2–45).

Adjust the linkage so the valve spool does not move when the steering lever is moved.

6. Connect the hydraulic hoses to the control valve and tighten (Fig. 2–47).

B–05259

Fig. 2–44 Connecting Tubelines

7. Add the correct fluid to the hydraulic/hydrostatic reservoir (See Section 8 for the correct fluid).

B–05309

Fig. 2–45 Connecting Linkage

8. Install the tire and wheel assembly.

9. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

10. Remove the jackstands from under the loader frame.

B–05302

2–4 HYDRAULIC PUMP

Fig. 2–46 Connecting Linkage

WARNING

Lift the loader and put jackstands under the frame so there is no danger of the loader falling and causing personal injury.

IMPORTANT

Be careful when turning the flow control valve. When the tester is connected this way, there is no relief valve in the system. DO NOT close the valve (on the tester) all the way.

B–05340

Fig. 2–47 Installing Hoses 48 of 256

–2–10–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

5. Connect all the linkages at the control valve (Fig. 2–46).

Checking Output of the Hydraulic Pump

A

This test will determine the acceptable flow of the hydraulic pump. A hydraulic tester is required that will measure flow, temperature and pressure.

NOTE: Make sure that all the air is removed from the system before beginning the test. Air in the system can give an inaccurate test.

1. Stop the engine.

2. Raise the operator cab (SeeParagraph 5–1.1, Page 5–1).

3. Remove the hose between the outlet of the hydraulic pump and the inlet of the hydrauliccontrol valve.

4. Connect the inlet of the tester to the outlet of the hydraulic pump [A].

5. Connect the outlet of the tester to the inlet of the hydraulic control valve.

B–05257

9. Open the restrictor on the tester andrecord the free flow (GPM) at full RPM. 10. Disconnect any attachment from the auxiliary quick couplers and operate the auxiliary control lever .

Record the high pressure (PSI) and the flow (GPM) at full RPM. 11. The high pressure flow must be at least 80% of free flow.

HIGH PRESSURE FLOW (GPM) %= X 100 FREE FLOW (GPM)

B–05299

C

12. A low percentage may indicate a failed hydraulic pump, or air in the system.

Dealer Copy -- Not for Resale

B

NOTE: Make sure that the restrictor valve on the tester is fully open.

6. Start the engine and run at low RPM. If no flow is indicated on the tester , the hoses are connected backwards.

7. Increase the engine RPM to full RPM. 8. Warm the hydraulic fluid to 140°F (60°C) by turning the restrictor knob on the tester to about 1000 PSI (6895 kPa). Do not exceed system relief pressure.

*Make reference to your Model loader, in the Technical Service Guide, for the system relief pressure and full RPM specifications. The system relief pressure must be per specification before the test is run.

2–4.2 Removal of the Hydraulic Pump

B–05296

When making repairs on the hydraulic system, keep all parts clean and remove the dirt from the area. Use caps and plugs to keep debris out of the tubelines or ports.

1. Remove the hydraulic/hydrostatic fluid from the reservoir (See Paragraph 1–5.3, Page 1–12).

2. Remove the front panel.

3. Remove the hydraulic hose from the pump [B].

4. Remove the port block from the pump (See Paragraph 3–5.1, Page 3–8).

5. Remove the two (2) bolts which hold the hydraulic pump to the hydrostatic pump [C].

49 of 256 Revised June 94

–2–11–

540, 543 Loader Service Manual

6. Remove the hydraulic pump from the hydrostatic pump (Fig. 2–51).

7. Remove the o–ring from the pump (Fig. 2–52).

B–05258

Fig. 2–51 Removing the Pump 2–4.3 Disassembly of Hydraulic Pump

B–05311

Fig. 2–52 Removing the Pump O–ring

the

2. Put a mark across the body of the pump for correct assembly.

B–05283

Fig. 2–53 Loosen Pump Bolts

B–05279

Fig. 2–54 Removing Pump Bolts

3. Loosen the four (4) bolts on the pump (Fig. 2–53).

4. Remove the four (4) bolts from the pump (Fig. 2–54).

5. Remove the end plate (Fig. 2–55).

B–05280

Fig. 2–55 Removing End Plate

B–05282

Fig. 2–56 Removing Spring

6. Remove the spring (Fig. 2–56).

7. Remove the o–ring (Fig. 2–57).

8. Remove the valve plate (Fig. 2–58).

50 of 256

B–05281

Fig. 2–57 Removing O–ring –2–12–

B–05292

Fig. 2–58 Removing Valve Plate 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

1. Put the hydraulic pump in the vise with the bolts in the up position.

9. Remove the cam ring 2–59).

(Fig.

10. Remove the dowel pins (Fig. 2–60).

11. Remove the rotor and vanes (Fig. 2–61).

B–05291

12. Remove the o–ring (Fig. 2–62).

Fig. 2–59 Removing Cam Ring

B–05293

Fig. 2–60 Removing Dowel Pins

1. Clean all the parts.

2. Check the cam ring (Fig. 2–63).

surface

B–05295

Fig. 2–61 Removing Rotor

B–05269

Fig. 2–62 Removing O–ring

3. Check the rotor and splines (Fig. 2–64).

4. Check the vanes for the rotor (Fig. 2–65).

5. Check all the parts for wear, scratches and other damage.

Replace the parts as needed.

B–05310

Fig. 2–63 Cam Ring Inspection

Dealer Copy -- Not for Resale

2–4.4 Inspection of the Hydraulic Pump

B–05271

Fig. 2–64 Rotor Inspection

2–4.5 Assembling the Hydraulic Pump NOTE: Install new o–rings and put oil on all the parts during assembly.

1. Put the pump body in the vise.

2. Install the pump body o–ring (Fig. 2–66).

51 of 256

B–05273

Fig. 2–65 Rotor Vane Inspection –2–13–

B–05269

Fig. 2–66 Installing O–ring 540, 543 Loader Service Manual

3. Install the rotor on the pump body (Fig. 2–67) and install the vanes in the rotor with the rounded edge of each vane toward the outside of the pump.

4. Install the dowel pins (Fig. 2–68).

B–05295

Fig. 2–67 Installing Rotor

B–05293

Fig. 2–68 Installing Dowel Pins

B–05291

6. Install the valve plate (Fig. 2–70).

Fig. 2–69 Installing Cam Ring

B–05292

Fig. 2–70 Installing Valve Plate

7. Install the o–ring (Fig. 2–71).

8. Install the spring (Fig. 2–72).

B–05281

Fig. 2–71 Installing O–ring

B–05282

Fig. 2–72 Installing Spring

9. Install a new o–ring in the pump end plate (Fig. 2–73).

10. Install the end plate (Fig. 2–74).

52 of 256

B–05288

Fig. 2–73 Installing O–ring –2–14–

B–05280

Fig. 2–74 Installing End Plate 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

5. Install the cam ring over the rotor (Fig. 2–69). Make surethe arrow on the housing points in the direction of the pump rotation.

11. Install the four (4) bolts and tighten (Fig. 75).

2–4.6 Installing the Hydraulic Pump 1. Install a new o–ring in the mounting flange of the hydraulic pump (Fig. 2–76).

2. Install the hydraulic pump on the hydrostatic pump (Fig. 77).

3. Install the two (2) bolts and tighten (Fig. 2–78).

4. Install the port block (See Paragraph 3–5.2, Page 3–8).

B–05283

5. Install the hose at the hydraulic pump.

Fig. 2–75 Tighten the Pump Bolts

6. Install the front panel.

2–4.7 Start–Up Procedure for the Hydraulic Pump

WARNING

Lift the loader and put jackstands under the frame so there is no danger of the loader falling and causing personal injury.

B–05311

2. Start the engine and run it at half engine RPM with no hydraulics engaged for several minutes.

Fig. 2–76 Installing the O–ring

3. Operate the hydraulic control valve to build up pressure at 3 second intervals for several minutes.

4. Increase the engine speed to full RPM and repeat step 3.

5. Slow the engine RPM to an idle and stop the engine. Check for leaks.

Dealer Copy -- Not for Resale

1. Add fluid to the hydraulic/hydrostatic reservoir as needed (See Section 8for the correct fluid).

6. Check the hydraulic/hydrostatic reservoir. Add fluid as needed.

7. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

8. Remove the jackstands from under the loader frame.

B–05258

Fig. 2–77 Installing the Pump 2.5 LIFT CYLINDERS 2–5.1 Checking the Lift Cylinders NOTE: The maximum cylinder drift allowed is 1.3” (33 mm) in 10 minutes with no bucket or attachment.

1. Lower the lift arms all the way down. Stop the engine. Activate all hydraulic controls to release the hydraulic pressure.

WARNING

the

Lift the loader and put jackstands under the frame so there is no danger of the loader falling and causing personal injury.

B–05296

Fig. 2–78 Tighten Pump Bolts 53 of 256

–2–15–

540, 543 Loader Service Manual

2. Open the rear door.

Left Side

3. Disconnect the hose from the tubeline which goes to the base end of the lift cylinder (Fig. 2–79 & 2–80). Install the plug in the tubeline.

4. Start the engine. Push the top (toe) of the lift pedal.

5. If there is oil leakage from the hose remove the cylinder or cylinders and make repairs as needed (See Paragraph 2–5.3).

6. Connect the hose or hoses and tighten them.

7. Close the rear door.

Remove Hose from Base End of Lift Cylinder B–02795R

Right Side

2–5.2 Removing the Lift Cylinder 1. Install the lift arm stop in the lift cylinder that is NOT GOING T O BE REMOVED. You can remove only one lift cylinder at a time using this method. (a) Two persons are needed to install the lift arm stop. One person must be in the operator seat with the seat belt fastened until the lift arm stop is installed. (b)

Start the engine and raise the lift arms all the way up.

(c) Have the second person install the lift arm stop over the rod of one cylinder (Fig. 2–81).

NOTE: Make sure the lift arm stop is tight against the cylinder rod.

Remove Hose From Base End of Lift Cylinder B–02794

Fig. 2–80 Checking Lift Cylinder

(d) Lower the lift arms until the stop is held between the lift arms and the lift cylinder. (e)

Stop the engine.

2. Activate the hydraulic controls to release the hydraulic pressure.

3. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

4. Open the rear door.

5. Disconnect the hoses at the base end of the cylinder (Fig. 2–82).

54 of 256

6558015

Fig. 2–81 Lift Arm Stop –2–16–

B–04391

Fig. 2–82 Disconnect the Hoses 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

Fig. 2–79 Checking Lift Cylinder

8. Remove the jackstands from under the loader frame.

6. Remove the locknut and the bolt at the rod end of the cylinder (Fig. 2–83).

7. Remove the pivot pin (Fig. 2–84). Make sure to support the lift cylinder when removing the pivot pin.

8. Remove the locknut and the bolt at the base end of the cylinder (Fig. 2–85).

9. Remove the pivot pin (Fig. 2–86).

10. Remove the lift cylinder from the loader.

B–04981

Fig. 2–83 Removing Lockbolt

the

NOTE: This procedure can be used for both the lift and tilt cylinders. The tools listed will be for either the tilt or lift cylinder.

The tools listed will be needed to do the following procedure: MEL–1075 – Gland Nut Wrench MEL–1076 – Cylinder Wrench

B–04968

Fig. 2–84 Removing Pivot Pin

B–05043

Fig. 2–85 Removing Lockbolt

NOTE: The photos in the figures may not be exactly the same as the cylinder you are working on.

1. Put the base end of the cylinder in a drain pan and move the rod in and out to remove the oil from the cylinder.

2. Put the base end of the cylinder in the vise.

B–05044

Fig. 2–86 Removing Pivot Pin

Dealer Copy -- Not for Resale

2–5.3 Disassembly of Hydraulic Cylinder

B–05025

Fig. 2–87 Removing End Cap

3. Remove the end cap from the cylinder with the special tool (Fig. 2–87).

4. Remove the rod with the end cap and piston from the cylinder (Fig. 2–88).

5. Remove the cylinder housing from the vise.

6. Put the rod end in the vise and remove the nut (Fig. 2–89).

55 of 256

B–03665

Fig. 2–88 Removing Piston & Rod –2–17–

B–03670

Fig. 2–89 Removing the Nut 540, 543 Loader Service Manual

7. Remove the piston from the rod (Fig. 2–90).

8. Remove the o–ring (Fig. 2–91).

9. Remove the end cap from the rod (Fig. 2–92).

B–03683

Fig. 2–90 Removing the Piston

B–03693

Fig. 2–91 Removing the O–ring

10. Remove the o–ring and back–up washer from the end cap (Fig. 2–93).

12. Remove the oil seal (Fig. 2–95).

B–03685

Fig. 2–92 Removing the End Cap

B–04678

Fig. 2–93 Removing the O–ring

13. Remove the teflon seal from the piston (Fig. 2–96).

14. Remove the o–ring on the piston (Fig. 2–97).

15. Wash all the parts in solvent.

Dry with air only . Destroy old seals and o–rings.

B–04672

Fig. 2–94 Removing Wiper Seal

B–04671

Fig. 2–95 Removing Oil Seal

2–5.4 Assembly of the Hydraulic Cylinder The tools listed will be needed to do the following procedure: MEL–1032–Rod Seal Tool MEL–1008–Seal Installation Tool (2”) MEL–1009–Seal Installation Tool (3”) MEL–10579–Cylinder Hone (2”) MEL–10064–Cylinder Hone (3”)

56 of 256

B–03689

Fig. 2–96 Removing Teflon Seal –2–18–

B–03703

Fig. 2–97 Removing the O–ring 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

11. Remove the wiper seal from the end cap (Fig. 2–94).

1. Make an inspection of the parts for scratches, nicks, bent, etc.

Replace parts as needed.

2. Install the piston over the tool (Fig. 2–98).

3. Install the o–ring on the piston using the tool (Fig. 2–99).

B–03674

Fig. 2–98 Installing the Piston Tool

B–03675

Fig. 2–99 Installing the O–ring

4. Install the teflon seal over the tool and on the piston (Fig. 2–100).

5. Install the piston into the tapered end of the tool (Fig. 2–101) to get the teflon seal to the piston size diameter. Leave the piston in the tool for 5 minutes so that the teflon seal will become the correct size.

B–03677

Fig. 2–100 Installing the Teflon Seal

B–03673

Fig. 2–101 Installing Piston in Tool

6. Install the wiper seal with thelip toward the outside of the end cap (Fig. 2–102).

NOTE: The o–ring side of the oil seal goes toward the inside of the cylinder.

B–03682

Fig. 2–102 Installing Oil Seal

Dealer Copy -- Not for Resale

NOTE: To prevent damage to the teflon seal, do not turn it into the piston groove.

B–03702

Fig. 2–103 Installing Oil Seal on Tool

7. Install the oil seal on the rod seal tool (Fig. 2–103).

8. Install the oil seal in the end cap (Fig. 2–104).

9. Install the back–up (Fig. 2–105).

57 of 256

washer

B–03671

Fig. 2–104 Installing Wiper Seal –2–19–

B–03679

Fig. 2–105 Installing Backup Washer 540, 543 Loader Service Manual

10. Install the o–ring (Fig. 2–106).

11. Put oil on the wiper seal and install the cap on the shaft (Fig. 2–107).

12. Install the o–ring on the shaft (Fig. 2–108).

B–03681

13. Remove the piston from the tool and install the piston on the shaft (Fig. 2–110).

Fig. 2–106 Installing O–ring

B–03685

Fig. 2–107 Installing End Cap

15. Inspect the cylinder bore for scratches. Use a hone to clean up the cylinder hone.

B–03693

16. Put oil on theseals, o–rings and end cap threads (Fig. 2–111).

Fig. 2–108 Installing O–ring

B–03692

Fig. 2–109 Installing Piston

17. Install the assembly in the cylinder housing (Fig. 2–112).

18. Tighten the end cap with the special tool (Fig. 2–113).

19. Push the cylinder rod in andout the full length of the cylinder housing. It must travel freely through the full stroke of the cylinder with no binding.

B–03670

Fig. 2–110 Tighten the Nut

B–03691

Fig. 2–111 Putting Oil on the Seals

2–5.5 Installation of the Lift Cylinder 1. Install the lift cylinder in the loader.

B–03665

Fig. 2–112 Installing Assembly 58 of 256

–2–20–

B–05025

Fig. 2–113 Tighten End Cap 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

14. Install the nut and tighten to 195–205 ft–lbs. (264–278 Nm) torque (Fig. 2–110).

2. Install the pin in the base endof the lift cylinder (Fig. 2–114).

3. Lift the rod end of the cylinder up into the lift arms and install the pin.

4. Install the bolt and locknut in the rod end pin (Fig. 2–115).

5. Install the bolt and locknut in the pin at the base end of the cylinder (Fig. 2–116).

B–04981

Fig. 2–115 Installing Bolt and Locknut

6. Connect the hydraulic hoses and tighten (Fig. 2–117).

B–04397

Fig. 2–114 Installing Pivot Pin 7. Close the rear door.

9. Operate the lift arms, stop the engine and check for leaks.

Dealer Copy -- Not for Resale

8. Start the engine. Have a second person remove the lift arm stop.

B–05043

10. Check the hydraulic/hydrostatic reservoir. Add fluid as needed.

Fig. 2–116 Installing Bolt and Locknut

2–6 TILT CYLINDER 2–6.1 Checking the Tilt Cylinder

1. Remove the bucket, roll the Bob–Tach fully backward and stop the engine.

Activate the hydraulic controls to release the hydraulic pressure.

Lift the loader and put jackstands under the frame so there is no danger of the loader falling and causing personal injury.

Remove Hose from Base End of the Tilt Cylinder

2. Install the pin in the base endof the lift cylinder (Fig. 2–114).

59 of 256

B–04391

Fig. 2–117 Tighten the Hoses –2–21–

B–02790

Fig. 2–118 Checking Tilt Cylinder 540, 543 Loader Service Manual

3. Start the engine. Push the bottom (heel) of the tilt pedal.

4. If there is leakage from the hose, remove the tilt cylinder for repair (See Paragraph 2–6.2).

5. If there is no leakage, connect the hoses and tighten.

6. Remove the jackstands from under the loader frame.

B–05104

Fig. 2–119 Bolt and Locknut

2–6.2 Removing the Tilt Cylinder

2. Activate the hydraulic controls to release the hydraulic pressure.

3. Remove the locknut and bolt from the pin at the rod end of the cylinder (Fig. 2–119).

B–05105

Fig. 2–120 Removing the Pivot Pin

4. Remove the pin at the rod end of the cylinder (Fig. 2–120).

5. Disconnect the hoses from the tilt cylinder (Fig. 2–121).

6. Remove the locknut and bolt from the base end of the tilt cylinder (Fig. 2–122).

B–02790

7. Remove the pin at the base end of the cylinder (Fig. 2–123).

Fig. 2–121 Hydraulic Hoses

B–04892

Fig. 2–122 Bolt and Locknut

8. Remove the tilt cylinder from the lift arms.

NOTE: When repairing the tilt cylinder, use the same procedure as when repairing the lift cylinders (See Paragraph 2–5.3).

Always use new o–rings when repairing the tilt cylinder.

60 of 256

B–04891

Fig. 2–123 Removing the Base End Pin –2–22–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

1. Stop the engine.

2–6.3 Installation of the Cylinder

Tilt

1. Install the tilt cylinder in the lift arms.

2. Install the base end pin into the tilt cylinder to hold in position.

3. Install the bolt and locknut and tighten to 16–20 ft.–lbs. (22 –27 Nm) torque (Fig. 2–122).

B–05113

Fig. 2–124 Installing the Rod End Pin 4. Connect the hydraulic hoses to the tilt cylinder and tighten (Fig. 2–121).

5. Install the rod end of the tilt cylinder in the Bob–Tach frame.

6. Install the pin in the rod end of the tilt cylinder (Fig. 2–124).

Dealer Copy -- Not for Resale

7. Install the bolt and locknut and tighten to 16–20 ft.–lbs. (22–27 Nm) torque (Fig. 2–119).

8. Add grease to the grease fittings.

9. Start the engine and operate the tilt cylinder. Stop the engine and check for leaks.

10. Check the hydraulic/hydrostatic reservoir. Add fluid as needed (See Section 8 for the correct fluid).

B–04916

2–7 HYDRAULIC/HYDROSTATIC RESERVOIR

Fig. 2–125 Harness Bracket

2–7.1 Removing the Hydraulic/Hydrostatic Reservoir 1. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

2. Remove the harness bracket (Fig. 2–125).

3. Remove the fluid from the reservoir (See Paragraph 1–5.3, Page 1–12).

4. Disconnect the hose at the bottom of the reservoir (Fig. 2–126).

5. Remove the bolt holding the strap in position (Fig. 2–127).

6. Remove the hydraulic/ hydrostatic reservoir.

61 of 256

B–04920

Fig. 2–126 Reservoir Hoses –2–23–

B–04919

Fig. 2–127 Reservoir Bracket 540, 543 Loader Service Manual

2–7.2 Installation of the Hydraulic/Hydrostatic Reservoir 1. Install the reservoir into the correct location.

2. Install the strap and tighten the bolt (Fig. 2–127).

3. Install the hose at the bottom of the reservoir (Fig. 2–126).

B–05163

Fig. 2–128 Hose Clamp

B–05164

Fig. 2–129 Hose Fitting

4. Install the harness bracket (Fig. 2–125).

6. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

7. Start the engine and operate the hydraulic controls. Stop the engine and check for leaks.

B–05262

Fig. 2–130 Hose Fitting

B–05261

Fig. 2–131 Air Shrouding Nut

8. Check the hydraulic/hydrostatic fluid and add as needed.

2–8 OIL COOLER 2–8.1 Removing the Oil Cooler (540) 1. Remove the hose clamp from the rear door (Fig. 2–128).

2. Disconnect the hoses from the elbow fittings at the oil cooler (Fig. 2–129 & 2–130). Install plugs in the hoses.

3. Remove the elbow fittings form the oil cooler and install plugs.

4. Remove the nuts that hold the air shrouding to the rear door (Fig. 2–131).

5. Remove the air shrouding from the rear door (Fig. 2–132).

62 of 256

B–05304

Fig. 2–132 Oil Cooler Air Shrouding –2–24–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

5. Fill the reservoir with the specified fluid (See Paragraph 1–5.2, Page 1–11).

6. Remove the oil cooler from the rear door (Fig. 2–133).

2–8.2 Installation of the Oil Cooler (540) 1. Install the oil cooler in the rear door. Make sure the oil cooler is pushed into the rubber mounting (Fig. 2–133).

2. Install the air shrouding overthe oil cooler (Fig. 2–132).

3. Install the nuts on the air shrouding and tighten (Fig. 2–131).

B–05303

Fig. 2–133 Oil Cooler

Dealer Copy -- Not for Resale

4. Remove the plugs from the oil cooler and install the elbow fittings in the oil cooler.

5. Remove the plugs from the hoses and connect the hoses to the oil cooler fittings and tighten (Fig. 2–129 & 2–130).

6. Install the hose clamp and tighten the nut (Fig. 2–128).

7. Start the engine and operate the loader. Stop the engine and check for leaks.

8. Check the hydraulic/ hydrostatic reservoir. Add fluid as needed.

2–8.3 Removing the Oil Cooler (543) 1. Remove the radiator from the loader (See Paragraph 7B–3.5, Page 7B–14).

B–05144

Fig. 1–134 Hose Fitting

B–05305

Fig. 2–135 Hose Fitting

2. Disconnect the hoses at the oil cooler (Fig.2–134 & 2–135).

3. Put plugs in the hoses (Fig. 2–136) and in the oil cooler fittings.

4. Remove the two (2) bolts at the rear of the oil cooler (Fig. 2–137).

63 of 256

B–05143

Fig. 2–136 Installing Plugs –2–25–

B–05307

Fig. 2–137 Rear Oil Cooler Bolts 540, 543 Loader Service Manual

5. Remove the two (2) bolts at the front of the oil cooler (Fig. 2–138).

6. Remove the oil cooler from the loader (Fig. 2–139).

2–8.4 Installing the Oil Cooler (543) 1. Install the oil cooler in the loader. Make alignment of the bolt holes (Fig. 2–139).

B–05256

Fig. 2–138 Front Oil Cooler Bolts

2. Install the front oil cooler bolts and tighten (Fig. 2–138).

3. Install the bolts in the oil cooler (Fig. 2–137) and tighten.

Dealer Copy -- Not for Resale

4. Remove the plugs from the hoses and the oil cooler and connect the hoses to the oil cooler (Fig. 2–134 & 2–135) and tighten.

5. Install the radiator in the loader (See Paragraph 7B–3.6, Page 7B–16).

6. Start the engine and operate the loader. Stop the engine and check for leaks.

7. Check the hydraulic/ hydrostatic fluid in the reservoir.

Add fluid as needed.

B–05306

Fig. 2–139 Oil Cooler 2–9 10 MICRON FILTER BY–PASS VALVE 2–9.1 Removing the By–pass Valve 1. Remove the hydraulic filter.

2. Remove the hoses and the tubelines from the filter head.

3. Remove the filter head (Fig. 2–140) from the loader.

4. Put the filter head in a vise.

5. Remove the plug (Fig. 2–141) from the filter head.

64 of 256

B–04904

Fig. 2–140 Filter Head –2–26–

B–04903

Fig. 2–141 By–pass Valve Plug 540, 543 Loader Service Manual

6. Remove the spring and poppet (Fig. 2–142).

7. Check the poppet and the seating area for damage. Check the o–ring on the plug for damage.

2–9.2 Installation of the By–pass Valve 1. Install the by–pass valve into the filter head (Fig. 2–142) and tighten the plug (Fig. 2–141).

2. Install the filter head into the loader (Fig. 2–140).

3. Connect the hose and the tubeline to the filter head.

B–04906

4. Install a new filter element on the filter head.

Fig. 2–142 By–pass Valve

2–10.1 Pedal

Dealer Copy -- Not for Resale

2–10 CONTROL PEDAL, LINKAGE AND LOCKS Removing the Control

1. Stop the engine and lower the lift arms.

Lift the loader and put jackstands under the frame so there is no danger of the loader falling and causing personal injury.

B–04473

Fig. 2–143 Pedal Linkage

B–04469

Fig. 2–144 Linkage Hair Pin

2. Disconnect the linkage fromthe pedal (Fig. 2–143).

3. Remove the hair pins from the pivot pins (Fig. 2–144).

Bolt (3.8 x 1–1/2”) Washer

4. Remove the pedal from the pivot bracket.

Bushing

B–04475

Pedal

5. Remove the bushing from the pedal.

2–10.2 Installing the Control Pedal 1. Using a vise, install a new bushing in the pedal (Fig. 2–145).

65 of 256

Neoprene Linkage

B–04383

Fig. 2–145 Install Pedal Bushings –2–27–

540, 543 Loader Service Manual

2. Start the pivot pins into the pedal (Fig. 2–146).

3. Put the pedal into the pivot bracket and push the pivot pins into position.

4. Install the hair pins (Fig. 2–144).

5. Connect the linkage at pedal (Fig. 2–143).

the B–04466

Fig. 2–146 Installing Pivot Pins

Fig. 2–147 Adjusting Bolts

Adjusting the Control

Dealer Copy -- Not for Resale

2–10.3 Pedal

B–04478

Loosen the nuts (Fig. 2–147) and slide the pivot bracket backward or forward until there is 1 1/2” (38 mm) under the rear edge of the pedal (Fig. 2–148). Tighten the nuts to 25–28 ft.–lbs. (34–38 Nm) torque.

1–1/2” (38 mm) 2–10.4 Pedal Lock Linkage A–02756

If you remove the pedal lock linkage, use the following procedure for installation:

Fig. 2–148 Control Pedal Adjustment

1. Install the bolts (Fig. 2–149, Item 1) from the outside of the fender.

2

2. Install a plastic washer (Fig. 2–149, Item 2).

3

2

3 3. Install the lock (Fig. 2–149, Item 3).

1 1

4. Put loctite on the threads of the bolts.

66 of 256

D–01548

Fig. 2–149 Pedal Lock Linkage –2–28–

540, 543 Loader Service Manual

5. Install the special nuts and plastic washers (Fig. 2–150). Make sure the special nut goes tight against the fender and thatthe plastic washers go over the shoulder of the special nut.

6. Tighten the special nut to 25 ft.–lbs. (34 Nm) torque.

7. Loosen the nuts on the tab (Fig. 2–151, Item 1). Put the pedalin the neutral position and tighten the nuts to 25 ft.–lbs. (34 Nm) torque.

AVOID INJURY OR DEATH

WARNING

Adjust locking tabs on pedal control linkage so that lift and tilt control pedals are locked in neutral when the seat bar is up.

W–2104–1285

B–05260

Dealer Copy -- Not for Resale

Fig. 2–150 Special Nut and Washer

B–04043

Fig. 2–151 Pedal Lock

67 of 256

Revised Oct. 98

–2–29–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 68 of 256

–2–30–

540, 543 Loader Service Manual

HYDROSTATIC SYSTEM Paragraph Number 3–6 3–7 3–2 3–5 3–3 3–4 3–1

HYDROSTATIC SYSTEM

Dealer Copy -- Not for Resale

HYDROSTATIC MOTOR . . . . . . . . . . . . . .

HYDROSTATIC PUMP . . . . . . . . . . . . . . . .

HYDROSTATIC SYSTEM INFORMATION PORT BLOCK . . . . . . . . . . . . . . . . . . . . . . .

STEERING LEVERS . . . . . . . . . . . . . . . . .

STEERING LINKAGE . . . . . . . . . . . . . . . . .

TROUBLESHOOTING . . . . . . . . . . . . . . . .

Page Number 3–9 3–18 3–2 3–8 3–3 3–5 3–1

WARNING

69 of 256

DO NOT service the Bobcat loader without instructions or taking the necessary safety precautions.

Before working on the loader , see the warnings and instructions at the beginning of this Service Manual.

After making the repair or adjustment, always check the function of the loader . Failure to obey warnings may cause injury or death.

–3––1–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 70 of 256

–3–0–

540, 543 Loader Service Manual

3 HYDROSTATIC SYSTEM 3–1 TROUBLESHOOTING The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

PROBLEM

CAUSE

No drive on one side, in one direction.

1, 2, 3, 4, 5

No drive on one side in both directions.

2, 3, 5, 6, 7, 8

The loader does not move in a straight line.

2, 3, 4, 6, 8, 9, 10

The hydrostatic system is overheating.

4, 11, 12, 13, 14, 15

The oil light comes “ON”.

16, 17, 18

1. The hydrostatic system has a fluid leak.

2. The steering linkage needs adjustment.

3. The high pressure replenishing valve(s) are defective.

4. The shuttle valve in the hydrostatic motor has a defect.

5. The balance plate in the hydrostatic motor seal is defective.

6. The hydrostatic pumps have a defect.

7. The final drive chain(s) is broken.

Dealer Copy -- Not for Resale

KEY TO CORRECT THE CAUSE

8. The hydrostatic motor has a defect.

9. The tires do not have the correct tire pressure.

10. The tires are not the same size.

11. The hydrostatic fluid is not at the correct level.

12. The oil cooler has a restriction (Externally or Internally).

13. The temperature sending switch is not operating correctly.

14. The control valve is not operating correctly.

15. The loader is not being operated at the correct RPM. 16. The sender has a defective.

17. There is low charge pressure.

18. The charge relief has a defect.

71 of 256

–3–1–

540, 543 Loader Service Manual

SYSTEM

IMPORTANT

CHARGE FLUID

FUNCTION 1

When making repairs on the hydrostatic system, keep all parts clean and remove all the dirt from the area before you begin disassembly. Always use caps and plugs to keep debris out of the system.

FUNCTION 2

Valve Moves for Charge Fluid Replacement

Valve Stays on Seat to Hold High Pressure for Drive

3–2.1 High Pressure Relief Replenishing Valves Function The high pressure relief replenishing valves are used both in forward and reverse travel (Fig. 3–1 and 3–2).

FUNCTION 3

Valve Release Very High Pressure to Protect System B–02805

Fig. 3–1 Forward Function of the Valve The functions of the high pressure relief replenishing valves are as follows:

CHARGE FLUID

1. Give replacement fluid to the low pressure side of the closed hydrostatic circuit.

Replacement fluid is needed because of the normal inside leakage and for cooling (Fig. 3–1, Function 1 and Fig. 3–2, Function 1).

2. To keep the high pressure flow of fluid out of the low pressure side of the closed hydrostatic circuit (Fig. 3–1, Function 2 and Fig. 3–2, Function 2).

FUNCTION 1 Valve Moves for Charge Fluid Replacement

3. They will also release very high pressure caused by a high overload when traveling in a forward direction (Fig. 3–1, Function 3).

See Paragraph 3–7.1 to check the valves.

FUNCTION 2

Valve Stays on Seat to Hold High Pressure for Drive

B–02804

Fig. 3–2 Reverse Function of the Valve 72 of 256

–3–2–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

3–2 HYDROSTATIC INFORMATION

3–3 STEERING LEVERS 3–3.1 Removing Steering Levers

1. Stop the engine.

2. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

B–05210

Fig. 3–3 Removing Front Panel

B–05327

Fig. 3–4 Removing Side Shield

Dealer Copy -- Not for Resale

3. Remove the front panel (Fig. 3–3).

4. Remove the bolts and remove the side shields (Fig. 3–4) on both sides.

5. Remove the bolts from the steering lever shields (Fig. 3–5) on both sides. The shields can be removed with the steering levers.

B–05328

Fig. 3–5 Removing Steering LeverShield

B–05329

Fig. 3–6 Disconnect Auxiliary Linkage

6. Disconnect the steering linkage at the steering levers (Fig. 3–7).

7. Disconnect the steering linkage at the steering levers (Fig. 3–7).

8. Remove the bolts at the pivot bearings (Fig. 3–8) both sides of the steering levers.

73 of 256

B–05330

Fig. 3–7 Disconnect Steering Linkage –3–3–

B–05331

Fig. 3–8 Removing Pivot Bearings 540, 543 Loader Service Manual

3–3.2 Repairing the Steering Levers 1. Remove the rubber bushings and teflon bushings from the steering levers.

2. Install new rubber bushings into the steering levers, using two (2) sockets and a vise (Fig. 3–10).

3. Install new teflon bushings on the steering levers (Fig. 3–11).

4. Install the two (2) steering levers assemblies together (Fig. 3–12).

5. Check the pivot bearings. Replace as needed.

B–05332

Fig. 3–9 Steering Lever Assembly

1. Install the steering levers assembly into the loader (Fig. 3–9).

2. Install the bolts and nuts in the pivot bearings (both sides) and tighten to 25–28 ft.–lbs. (34–38 Nm) torque (Fig. 3–8).

B–04450

Spacer Washer

3. Install the steering linkage (Fig. 3–7) do not tighten the nuts.

4. Connect the auxiliary linkage at the right steering lever (Fig. 3–6). Adjust the linkage so when the steering lever is moved, for loader travel, the linkage does not move in or out.

5. Install the bolts in the steering lever shields and tighten (Fig. 3–5).

Bolt (3/8” x 1–5/8”) Neoprene Bushing

C–02662

Fig. 3–10 Installing Bushings

Teflon Bushing

Teflon Bushing

6. Install the side shields (both sides) and bolts and tighten (Fig. 3–4).

7. Install the front panel (Fig. 3–3).

8. Make adjustment of the steering linkage (See Paragraph 3–4.1).

9. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

74 of 256

B–04448

Fig. 3–11 Installing Teflon Bushing –3–4–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

3–3.3 Installing the Steering Levers

3–4 STEERING LINKAGE 3–4.1 Adjustment of the Steering Linkage

Lift the loader and put jackstands under the frame so there is no danger of the loader falling and causing personal injury.

Teflon Bushing B–04447

Dealer Copy -- Not for Resale

Fig. 3–12 Installing Steering Levers Together

DO NOT work on the loader with the lift arms in a raised position without support. Use lift arm stop or other methods.

1. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

B–05333

2. Loosen the nuts and bolts at the steering levers (Fig. 3–13).

Fig. 3–13 Steering Linkage Bolts

B–05338

Fig. 3–14 Pintle Lever Bolts

3. Loosen the nuts and bolts at the pintle levers (Fig. 3–14).

4. Loosen the nuts and bolts at steering linkage at the steering lever.

5. Start the engine and run at a slow RPM (See Paragraph 5–1.3).

6. Move the left steering lever until the tires do not turn (neutral).

7. Adjust the rear pintle bar (Fig. 3–15) so that the bar is tight against both lobes of the pintle lever and the transmission is still in the neutral position. ighten T the bolts on the bar to 28 ft.–lbs. (38 Nm) torque.

8. Move the left steering lever forward and backward and let the transmission return to the neutral position. If the transmission does not return to the neutral position, make the adjustment again.

75 of 256

–3–5–

B–05334

Fig. 3–15 Pintle Bar Bolts 540, 543 Loader Service Manual

9. Move the right steering lever until the tires do not turn (neutral).

10. Adjust the front pintle bar so that the bar is tight against bolt lobes of the pintle lever and the transmission is still in the neutral position (Fig. 3–16).

Tighten the bolts on the bar to 28 ft.–lbs. (38 Nm) torque.

11. Move both steering levers forward and backward and let them return to neutral position, make the adjustment if the transmission does not return to neutral.

B–05335

Fig. 3–16 Pintle Bar Bolts

B–05333

Fig. 3–17 Steering Linkage Bolts

Dealer Copy -- Not for Resale

12. Install new locknuts on each bolt that holds the steering linkage to the pintle levers and tighten to 23 ft.–lbs. (31 Nm) torque.

13. Install new locknuts on the bolts at the front end of the steering linkage and tighten to 23 ft.–lbs.

(31 Nm) torque.

14. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

15. Remove the jackstands from under the loader frame.

B–05338

Fig. 3–18 Pintle Lever Bolts

B–05336

Fig. 3–19 Removing the Bar

3–4.2 Removing the Steering Linkage 1. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

2. Remove the nuts and bolts at the steering levers (Fig. 3–17).

3. Remove the nuts and bolts at the pintle lever (Fig. 3–18).

4. Remove the bolts and nut at the bar by the centering spring (Fig. 3–19).

5. Loosen the bolts at the pintle levers.

6. Remove the centering bar, bushings and pintle levers as an assembly from the hydrostatic pumps (Fig. 3–20).

B–05339

Fig. 3–20 Removing the Centering Bar 76 of 256

–3–6–

540, 543 Loader Service Manual

3–4.3 Repairing the Pintle Lever

Front Pintle Lever

Washer

1. Remove the lobes from the pintle lever (Fig. 3–21).

Neoprene Bushing

2. Remove the rubber bushing from the pintle lever.

B–04386

Rear Pintle Lever

3. Install the new rubberbushings, using two (2) sockets and a vise (Fig. 3–22) in the pintle lever.

B–04470

Fig. 3–21 Pintle Lever Lobes 4. Install the new lobes on the pintle lever and tighten the bolts to 25–28 ft.–lbs.

(34–38 Nm) torque (Fig. 3–23).

Washer

3–4.4 Installing the Steering Linkage

Neoprene Bushing B–04385

1. Install the bushing and guide in the pintle lever.

3. Tighten the bolt on the pintle lever to 18–20 ft.–lbs. (24–27 Nm) torque.

Dealer Copy -- Not for Resale

2. Install the key on the shaft of the hydrostatic pump (Fig. 3–24) and install the pintle lever assembly.

B–04471

Fig. 3–22 Installing Bushings

4. Install the centering bar into the teflon guides on the front and rear pintle levers.

5. Install the bar on the centering spring bolt.

6. Install the bolt in the bar and tighten.

B–04476

Fig. 3–23 Tighten Pintle Lever Lobes 7. Adjust the centering spring bolt until it is even with the bar on the back side (Fig. 3–25).

8. Install the steering linkages on the pintle levers and the steering levers. Install the bolts and new locknut. DO NOT tighten them.

9. Make the adjustment to the steering linkage (See Paragraph 3–4.1).

77 of 256

B–04463

Fig. 3–24 Installing Pintle Lever –3–7–

B–05337

Fig. 3–25 Adjusting Centering Spring 540, 543 Loader Service Manual

3–5 PORT BLOCK 3–5.1 Removing the Port Block

IMPORTANT

Always use caps or plugs in openings or ports to keep debris out of the hydrostatic system.

B–05340

1. Stop the engine, remove the hydraulic/hydrostatic fluid from the reservoir (See paragraph 1–5.3, Page 1–12).

Fig. 3–26 Removing Hose at Valve

2. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

3. Remove the hose at the control valve (Fig. 3–26).

5. Remove the large nut at the top of the port block (Fig. 3–28).

6. Loosen the slotted bolt and remove the port block from the hydraulic pump (Fig. 3–29).

B–05347

Fig. 3–27 Removing Hose at Port Block

3–5.2 Installing the Port Block 1. Clean all the parts in solvent before assembling. Install new o–rings.

2. Install the port block and tighten the slotted bolt to 90–100 ft.–lbs. (125–135 Nm) torque.

B–05345

3. Install the large nut and tighten (Fig. 3–28).

Fig. 3–28 Large Nut at Port Block

4. Connect the hose at the port block and tighten (Fig. 3–27).

5. Connect the hose at the control valve and tighten (Fig. 3–26).

6. Add fluid to the hydraulic/hydrostatic reservoir (See Section 8 for the correct fluid).

7. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

B–05346

Fig. 3–29 Slotted Bolt at Port Block 78 of 256

–3–8–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

4. Remove the hose at the port block (Fig. 3–27).

3–5.3 By–Pass Valve 1. Stop the engine. Remove the hydraulic/hydrostatic fluid from the reservoir (See Paragraph 1–5.3, Page 1–12).

2. Remove the hose from the port block (Fig. 3–30).

3. Remove the fitting from the port block.

4. Remove the spring and valve (Fig. 3–31).

B–05347

Fig. 3–30 Removing the Hose

5. Clean and inspect the parts, replace as needed.

6. Install new o–ring and install the valve, spring and fitting.

7. Connect the hose to the port block and tighten (Fig. 3–30).

9. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

B–05344

3–6 HYDROSTATIC MOTOR

IMPORTANT

Dealer Copy -- Not for Resale

8. Add the correct fluid to the reservoir (See Section 8 for the correct fluid).

Fig. 3–31 Relief Valve

When making repairs on the hydrostatic system, keep all parts clean and remove all the dirt from the area before you begin disassembly.

Always use caps or plugs to keep debris out of the system.

3–6.1 Removing the Hydrostatic Motor

WARNING

Lift the loader and put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

WARNING

DO NOT work on the loader with the lift arms in a raised position without support. Use lift arm stops or other methods.

1. Remove the wheel assembly from the side of the loader where the motor is going to be removed.

79 of 256

–3–9–

540, 543 Loader Service Manual

2. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

3. Remove the hydrostatic pumps (See Paragraph 3–7.4).

4. Remove the cover/brake assembly (See Paragraph 4–1.2, Page 4–1).

B–05341

Fig. 3–32 Removing Cover Bolts

B–05342

Fig. 3–33 Removing Motor Cover

Dealer Copy -- Not for Resale

5. Only the front drive chain has to be removed so that the motor can be removed (See Paragraph 4–2.1, Page 4–5).

6. Remove the motor cover bolts (Fig. 3–32).

7. Remove the motor cover (Fig. 3–33).

B–05343

Fig. 3–34 Removing Case Drain Hose

B–05349

Fig. 3–35 Removing High Pressure Hoses

8. Disconnect the case drain hose (Fig. 3–34).

9. Disconnect the high pressure hoses (Fig. 3–35).

10. Remove the hydrostatic motor bolts (Fig. 3–36).

11. Move the hydrostatic motor so that the rear drivechain can be removed from the motor sprocket. Remove the motor from the loader.

B–05350

Fig. 3–36 Removing Motor Bolts 80 of 256

–3–10–

540, 543 Loader Service Manual

3–6.2 Disassembly of Hydrostatic Motor

the

NOTE: Clean the outside of the motor before disassembly. Keep all the parts of the motor clean.

B–03385

Fig. 3–37 Removing the Sprocket

Dealer Copy -- Not for Resale

1. Remove the sprocket from the motor with a hydraulic press or a puller (Fig. 3–37).

C–02362

2. Put the motor in a vise, remove the bolts holding the end cover to the motor (Fig. 3–38).

B–05351

Fig. 3–38 End Cover Bolts

B–05352

Fig. 3–39 Prying Motor Housing

3. Using a pry bar , lift up on the motor housing (Fig. 3–39) and remove the housing (Fig. 3–40).

4. Remove the commutator plate (Fig. 3–41).

81 of 256

B–05353

Fig. 3–40 Removing Housing –3–11–

B–02870R

Fig. 3–41 Removing Commutator Plate 540, 543 Loader Service Manual

5. Remove the commutator (Fig. 3–42).

6. Remove the seal from the commutator ring (Fig. 3–43).

B–05354

Fig. 3–42 Removing Commutator

B–05355

Fig. 3–43 Removing the Seal

8. Remove the manifold plate (Fig. 3–45).

B–02868

Fig. 3–44 Removing Manifold

B–02866

Fig. 3–45 Removing Manifold Plate

9. Remove the stator ring and rotor assembly (Fig. 3–46).

10. Remove the wear plate (Fig. 3–47).

B–02864

Fig. 3–46 Removing Rotor Assembly

B–02863

Fig. 3–47 Removing Wear Plate

11. Remove the drive link (Fig. 3–48).

12. Remove the thrust bearing (Fig. 3–49).

82 of 256

B–05356

Fig. 3–48 Removing Drive Link –3–12–

B–05358

Fig. 3–49 Removing Thrust Bearing 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

7. Remove the manifold (Fig. 3–44).

13. Remove the shuttle spring (Fig. 3–50).

14. Remove the shuttle valve (Fig. 3–51).

15. Remove the drive shaft (Fig. 3–52).

B–05359

Fig. 3–50 Removing Shuttle Spring

B–05360

Fig. 3–51 Removing Shuttle Valve

17. Remove the spacer (Fig. 3–54).

B–05361

Fig. 3–52 Removing Drive Shaft

B–05362

Fig. 3–53 Removing Snap Ring

18. Remove the back–up washer and seal (Fig. 3–55).

3–6.3 Inspection of the Hydrostatic Motor

B–05363

Fig. 3–54 Removing Spacer

Dealer Copy -- Not for Resale

16. Turn the flange housing over in the vise, using a snap ring pliers, remove the snap ring (Fig. 3–53).

B–05364

Fig. 3–55 Back–Up Washer & Seal

Clean and inspect all the parts for scratches, wear and damage, make an inspection of the following parts:

(a) Housing Wear Plate (Fig. 3–56).

(b) Install the stator ring and rotor assembly (Fig. 3–73).

83 of 256

B–05365

Fig. 3–56 Housing Wear Plate Inspection –3–13–

B–05366

Fig. 3–57 Manifold Inspection 540, 543 Loader Service Manual

(c) Manifold 3–58).

Plate

Fig.

(d) Stator and Rotor Assembly (Fig. 3–59).

(e) Wear Plate (Fig. 3–60).

(f) Commutator Ring (Fig. 3–61).

B–05367

Fig. 3–58 Manifold Plate Inspection

B–05369

Fig. 3–59 Stator & Rotor Inspection

3–6.4 Assembling the Hydrostatic Motor The tools listed will be needed to do the following procedure: B–05368

MEL–1017 Seal Installation Tool

Fig. 3–60 Wear Plate Inspection

B–05370

Fig. 3–61 Commutator Ring Inspection

1. Clean all the parts throughly and use all new seals and o–rings. Put fluid on all the parts during assembly.

2. Using the seal installation tool, install the rubber seal inside the housing with the lip of the seal to the inside of the motor (Fig. 3–62).

B–05364

Fig. 3–62 Installing Seal

B–05363

Fig. 3–63 Installing Spacer

3. Install the spacer with the chamfer toward the housing (Fig. 3–63).

4. Install the snap ring in the housing (Fig. 3–64).

5. Turn the housing over in the vise, install a new o–ring (Fig. 3–65).

84 of 256

B–05362

Fig. 3–64 Installing Snap Ring –3–14–

B–02873

Fig. 3–65 Installing O–Ring 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

(g) Shuttle Valve & Shuttle Springs

6. Install the drive shaft into the housing (Fig. 3–66).

7. Install one of the shuttle springs in the housing (Fig. 3–67).

B–05361

Fig. 3–66 Installing Drive Shaft

B–05359

Fig. 3–67 Installing Shuttle Spring

9. Install the second shuttlespring (Fig. 3–69).

B–05360

Fig. 3–68 Installing Shuttle Valve

B–05359

Fig. 3–69 Installing Shuttle Spring

10. Install the thrust bearing (Fig. 3–70).

11. Install the drive link (Fig. 3–71).

B–05358

Fig. 3–70 Installing Thrust Bearing

Dealer Copy -- Not for Resale

8. Install the shuttle valve (Fig. 3–68).

B–05356

Fig. 3–71 Installing Drive Link

12. Install the wear plate (Fig. 3–72).

13. Install the stator ring and rotor assembly (Fig. 3–73).

85 of 256

B–02863

Fig. 3–72 Installing Wear Plate –3–15–

B–02864

Fig. 3–73 Installing Rotor Assembly 540, 543 Loader Service Manual

14. Install the manifold plate (Fig. 3–74).

15. Install the manifold (Fig. 3–75).

B–02866

Fig. 3–74 Installing Manifold Plate

B–02868

Fig. 3–75 Installing Manifold

B–05355

Fig. 3–76 Installing Seal

B–05354

Fig. 3–77 Installing Commutator Ring

17. Install the commutator ring(Fig. 3–77).

18. Install the commutator plate (Fig. 3–78).

B–02870R

Fig. 3–78 Installing Commutator

B–05353

Fig. 3–79 Installing the Housing

19. Install the housing over the motor assembly (Fig. 3–79).

20. Install the bolts into the motor housing and tighten to 50 ft.–lbs. (68 torque (Fig. 3–80).

86 of 256

–3–16–

Nm)

B–05351

Fig. 3–80 Tighten End Cover Bolts 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

16. Install a new seal in the commutator ring (Fig. 3–76).

3–6.5 Installing the Hydrostatic Motor 1. Install the hydrostatic motor so that the rear drive chain can be installed on the motor sprocket.

2. Install the bolts into the motor housing and tighten the bolts to 100–110 ft.–lbs. (136–149 Nm) torque (Fig. 3–81).

3. Connect the high pressure hoses to the motor (Fig. 3–82).

4. Connect the case drain hose (Fig. 3–83).

B–05350

Fig. 3–81 Installing Motor Bolts

B–05349

Fig. 3–82 Installing the Hoses

5. Install the motor cover (Fig. 3–84).

Dealer Copy -- Not for Resale

6. Install the motor cover bolts and tighten (Fig. 3–85).

7. Install the front drive chain (See Paragraph 4–2.2, Page 4–6).

8. Tighten the nut at the end of the sprocket on the motor shaft to 260–300 ft.–lbs. (352–407 Nm) torque.

9. Install the cover/brake assembly (See Paragraph 4–1.4, Page 4–3).

B–05343

Fig. 3–83 Installing Case Drain Hose

B–05342

Fig. 3–84 Installing Motor Cover

10. Install the hydrostatic pumps (See Paragraph 3–7.8).

11. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

12. Add the correct fluid to the reservoir (See Section 8 for the correct fluid).

3–6.6 Start–Up Procedure for the Hydrostatic Motor Because of the close tolerances in the hydrostatic motor, it is important that the motor is NOT OPERATED WITHOUT A LOAD when the motor is first used after being repaired.

The motor must be replaced under a “full load” condition for at least 10 minutes.

“Full load” can be done by pushing some heavy object or material.

B–05341

Fig. 3–85 Installing Cover Bolts 87 of 256

–3–17–

540, 543 Loader Service Manual

3–7 HYDROSTATIC PUMP

IMPORTANT

When making repairs on the hydrostatic system, keep all parts clean and remove all the dirt from the area before you begin disassembly.

Always use caps or plugs to keep debris out of the system.

This Side Toward The Engine

3–7.1 Checking the High Pressure Relief Replenishing V alves

NOTE: Check the hydrostatic pump on the side only where thedrive is lost.

WARNING

Lift the loader and put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

WARNING

DO NOT work on the loader with the lift arms in a raised position without support. Use lift arm stops or other methods.

Reverse Forward

Replenishing High Pressure Relief Valves

B–01608

Fig. 3–86 Replenishing Valves 1. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

2. Remove the plug for one direction.

3. Remove the spring and high pressure relief replenishing valve (Fig. 3–86).

4. Remove the plug for the other direction.

5. Remove the spring and high pressure relief replenishing valve.

6. Change the valves to the opposite ports where they were removed.

7. Install the springs and plugs. Start the engine and check the drive.

8. If the loss of the drive goes to the other direction of the loader , the valvewhich controls that direction of the loader must be replaced.

9. If the changing of the valves does not change the direction of loss of drive.

The problem is somewhere else in the system, go to the troubleshooting chart for other possible causes.

10. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

11. Remove the jackstands from under the loader frame.

88 of 256

–3–18–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

If there is a loss of drive in one direction, to one side of the loader, use the following procedure to check the high pressure relief replenishing valves:

3–7.2 Checking the Charge Pressure The tools listed will be needed to do the following procedure: MEL–1173 – Test Kit

WARNING

Lift the loader and put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

B–03457

Fig. 3–87 Checking Charge Pressure

WARNING

DO NOT work on the loader with the lift arms in a raised position without support. Use lift arm stops or other methods.

2. Disconnect the wire from the pressure switch on the side of the hydrostatic pump.

3. Remove the pressure switch.

Dealer Copy -- Not for Resale

1. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

B–05371

Fig. 3–88 Charge Pressure Plug 4. Connect a pressure gauge (Fig. 3–87).

5. Start the engine and run it at 2500 RPM. 6. The pressure on the gauge must read 45–65 PSI (310–448 kPa) minimum with no hydraulic action.

7. If the pressure is not correct, remove the plug (Fig. 3–88) and remove the spring and poppet (Fig. 3–89).

8. Check the poppet and seat area, replace parts as needed or repair hydrostatic pump (See Paragraph 3–7.5).

B–05372

Fig. 3–89 Charge Pressure Spring & Poppet

9. Replace the poppet and spring, tighten the plug.

10. Remove the gauge, install the pressure switch and connect the wire.

11. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

12. Remove the jackstands from under the loader frame.

3–7.3 Cold Weather By–Pass Valve If the “TRANS” indicator light continues to go “ON” and “OFF” and you do not notice any poor hydrostatic performance, the by–pass valve can be the problem.

89 of 256

–3–19–

540, 543 Loader Service Manual

1. Stop the engine. Remove the hydraulic/hydrostatic fluid from the reservoir (See Paragraph 1–5.3, Page 1–12).

2. Disconnect the hose from the port block. Remove the poppet and spring out of the port block (Fig. 3–90).

3. Check the spring and poppetfor damage or binding in the seat area.

B–03127

4. Assembly is the reverse of disassembly.

Fig. 3–90 Cold Weather By–Pass Valve

3–7.4 Removing the Hydrostatic Pumps B–05330

Fig. 3–91 Steering Linkage

Dealer Copy -- Not for Resale

WARNING

Lift the loader and put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

DO NOT work on the loader with the lift arms in a raised position without support. Use lift arm stop or other methods.

1. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

B–05348

Fig. 3–92 Steering Linkage

2. Remove the front panel.

3. Remove the side shields (both sides).

4. Remove the steering linkage at the steering levers (Fig. 3–91).

B–05374

Fig. 3–93 Removing Hoses

5. Remove the steering linkage at the pintle arms (Fig. 3–92).

6. Remove the fluid from the hydraulic/hydrostatic reservoir (See Paragraph 1–5.3, Page 1–12).

7. Remove the hoses from the hydraulic pump (Fig. 3–93) and from the port block.

8. Remove the high pressure hoses from the hydrostatic pumps (Fig. 3–94, 3–95) and install caps and plugs.

90 of 256

B–05375

Fig. 3–94 Removing Hoses (540) –3–20–

B–05373

Fig. 3–95 Removing Hose (543) 540, 543 Loader Service Manual

9. Remove the front pump mount bolts (both sides) (Fig. 3–96).

10. Remove the bolts (both sides) from the rear of the hydrostatic pump (Fig. 3–97).

11. Slide the pump assembly forward and lift up on it to remove it from the loader (Fig. 3–98).

B–05377

Fig. 3–97 Rear Pump Mounting Bolts

B–05376

Fig. 3–96 Front Pump Mounting

the

Dealer Copy -- Not for Resale

3–7.5 Disassembly of Hydrostatic Pumps

IMPORTANT Keep all the hydrostatic parts clean. Dirt in the system will cause damage in a very short time.

B–05378

1. Remove the steering linkage from the hydrostatic pumps (See Paragraph 3–4.2).

Fig. 3–98 Removing the Hydrostatic Pump Assembly

2. Remove the port block fromthe hydraulic pump (See Paragraph 3–5.1).

3. Remove the hydraulic pump (See Paragraph 2–4.2, Page 2–11).

4. Remove the coupler assembly from the pump shaft (Fig. 3–99).

91 of 256

B–02894

Fig. 3–99 Removing Coupler Assembly –3–21–

540, 543 Loader Service Manual

5. Put a mark across all the pump sections for correct assembly.

6. Remove the plug and the high pressure replenishing valves (both sides) (Fig. 3–100).

B–05379

Fig. 3–100 Removing Valves

Fig. 3–101 Removing Spring & Poppet

8. Remove the four (4) bolts from the housing and center section (Fig. 3–102).

9. Separate the pump housing from the center section (Fig. 3–103).

B–05381

Fig. 3–102 Removing Housing Bolts

B–05382

Fig. 3–103 Separating Pump Housing

10. Remove the coupling from the center section (Fig. 3–104).

11. Remove the four (4) bolts from the other housing and center section (Fig. 3–105) and remove the pump housing.

B–05384

Fig. 3–104 Removing Coupling

B–06385

Fig. 3–105 Removing Housing Bolts

12. Put the pump housing in a vise.

Remove the snap ring from the shaft (Fig. 3–106).

13. Remove the race from the shaft (Fig. 3–107).

92 of 256

B–05388

Fig. 3–106 Removing Snap Ring –3–22–

B–05389

Fig. 3–107 Removing the Race 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

7. Remove the plug and the charge pressure spring and poppet (both sides) (Fig. 3–101).

B–05380

IMPORTANT Keep all the parts for one pump separated from the parts for the other pump.

B–05386

Fig. 3–108 Removing Rotating Group

B–05387

Fig. 3–109 Removing the Shaft

15. Turn the front housing around and hit the shaft on a block of wood to remove the shaft from the housing (Fig. 3–109).

B–05390

Fig. 3–110 Removing the Snap Ring

Dealer Copy -- Not for Resale

14. Remove the pump housing from the vise and remove the rotating group by putting your hand under the rotating group and turn the pump housing around so the rotating group will slide into your hand (Fig. 3–108).

B–05392

Fig. 3–111 Removing the Shaft

16. Remove the snap ring (Fig. 3–110) from the rear housing and hit on a block of wood to remove the bearing and shaft (Fig. 3–111).

17. Remove the back–up washer (Fig. 3–112).

B–05393

Fig. 3–112 Removing the Back–Up Washer

B–05391

Fig. 3–113 Removing the Seal

18. Using a punch, remove the seal from the rear housing (Fig. 3–113).

19. Remove the snap ring (Fig. 3–114) and the bearing from the shaft for the rear housing.

20. Remove the cover on the long pintle shaft (Fig. 3–115).

93 of 256

B–05394

Fig. 3–114 Removing the Snap Ring –3–23–

B–05395

Fig. 3–115 Removing Pintle Shaft Cover 540, 543 Loader Service Manual

21. Remove the o–rings from the shaft (Fig. 3–116).

22. Remove the cover from the short pintle shaft (Fig. 3–117).

B–05397

Fig. 3–116 Removing O–Rings

B–05398

Fig. 3–117 Removing Pintle Shaft Cover

24. Loosen the bolts on the cam plate (Fig. 3–119) and remove the bolts.

B–05399

Fig. 3–118 Removing O–Rings

B–05400

Fig. 3–119 Cam Plate Bolts

25. Remove the pintle shafts from the cam plate and remove the cam plate from the housing (Fig. 3–120).

B–05401

Fig. 3–120 Removing Cam Plate 26. Check the pintle shaftbearings, if they need replacing, use a press to remove and install the new bearing (Fig. 3–121).

27. Check the bearings in the center section, use a punch to remove them (Fig. 3–122) and a press to install the new bearings.

B–05402

Fig. 121 Pintle Shaft Bearings 94 of 256

–3–24–

B–05403

Fig. 3–22 Removing Center Section Bearings 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

23. Remove the o–rings from the shaft (Fig. 3–118).

3–7.6 Inspection of the Hydrostatic Pumps

IMPORTANT Keep all the parts for one pump separated from the parts for the other pump.

B–05404

Fig. 3–123 Drive Shaft Inspection

B–05405

Fig. 3–124 Center Section Inspection

2. Inspect the flat surface of the center section, front and rear (Fig. 3–124). The finish on the piston block side must be smooth and free of grooves. If grooves can be felt on the finished surface with a fingernail, replace the section.

3. Inspect the rotating group for the following items: (a) Check each piston in its cylinder. he piston must move freely in the bore. If the piston does not move easily, clean the piston and bore.

Put oil on both and try again. (b) Check the piston shoe for scratches (Fig. 3–125).

B–05406

Fig. 3–125 Piston Shoe Inspection

Dealer Copy -- Not for Resale

1. Check the drive shafts for wear and damage to the splines (Fig. 3–123).

B–05407

Fig. 3–126 Piston Block Inspection

This Dimension Must be Maintained on All Nine Shoes Within 0.001 in. (0,0254 mm)

Piston

Shoe

Shoe Faces Sides On Swash Plate

Shoe Must Swivel Smoothly on Ball, End Play Must Not Exceed .003 in. (0,076 mm) A–01850

Fig. 3–127 Piston/Shoe Specifications

(c) Check the flat surface of the piston block for being smooth and free of scratches (Fig. 3–126). (d) Check the end play of each piston assembly. End play must not be more than 0.003” (0,076 mm) between the piston and the shoe (Fig. 3–127). (e) Measure the thickness of each shoe. All the shoes must be within 0.001” (0,025 mm) of each other.

95 of 256

–3–25–

540, 543 Loader Service Manual

(f) Inspect the shoe plate for wear and cracks. (g) Inspect the pins and spherical washer for wear and damage (Fig. 3–128).

All the pins must be the same length and must not be bent.

Check the spherical washer for sharp edges, wear or scratches.

B–05408

Fig. 3–128 Spherical Washer Inspection

B–05409

Fig. 3–129 Camplate Plate Inspection

4. Inspect the cam plate for scratches in the pintle shaft area. Inspect the cam plate plate (Fig. 3–129), the finish must be smooth and free of grooves. If grooves can be felt with the fingernail, replace the cam plate plate.

5. Inspect the races for the center section bearings (Fig. 3–130).

B–05405

Fig. 3–130 Center Section Inspection

B–05326

Fig. 3–131 Installing the Key

3–7.7 Assembling the Hydrostatic Pumps

IMPORTANT Use a top grade grease such as Dow Corning #44 or Vaseline petroleum jelly to lubricate the seals, o–rings or bearings.

B–05401

Fig. 3–132 Installing the Cam Plate

B–05400

Fig. 3–133 Tighten the Cam Plate Bolts

NOTE: Always use a NEW seal kit when assembling the hydrostatic pumps.

1. Install the key in the cam plate housing (Fig. 3–131).

2. Install the cam plate housing into the housing (Fig. 3–132).

B–05399

Fig. 3–134 Installing O–Rings 96 of 256

–3–26–

B–05397

Fig. 3–135 Installing O–Rings 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

NOTE: If there is any defect in the rotating group, the complete unit must be replaced.

3. Install the pintle shafts into the cam plate housing.

4. Install the bolts into the cam plate housing and tighten to 45 ft.–lbs. (61 Nm) torque (Fig. 3–133).

B–05398

Fig. 3–136 Installing Pintle Cover

B–05395

Fig. 3–137 Installing Pintle Cover

5. Install the o–rings on the pintle shafts (Fig. 3–134 & 1–135).

7. Install the bearings on the shafts.

Dealer Copy -- Not for Resale

6. Install the covers on the pintle shafts (Fig. 3–136 & 3–137) and tighten the bolts.

B–05393

Fig. 3–138 Installing Back–Up Washer 8. Install the seal in the rear housing.

9. Install the back–up washer in the housing (Fig. 3–138).

10. Install the shaft into the housing and install the snap ring (Fig. 3–139).

B–05388

Fig. 3–139 Installing Snap Ring 11. Install the rotating group on the shaft and into the pump housing.

12. Put the pump housing into a vise. Install the bearing race for the center section (Fig. 3–140).

13. Install the snap ring on the shaft (Fig. 3–141).

97 of 256

Revised June 94

B–05389

Fig. 3–140 Installing Race –3–27–

B–05390

Fig. 3–141 Installing Snap Ring 540, 543 Loader Service Manual

14. Install the pump housing to the center section and tighten the bolts to 42 ft.–lbs. (57 Nm) torque (Fig. 3–142).

B–05382

Fig. 3–142 Installing Pump Housing

B–05384

Fig. 3–143 Installing Coupling

16. Install the other pump housing and tighten the bolt to 42 ft.–lbs. (57 Nm) torque (Fig. 3–144).

B–05381

Fig. 3–144 Installing Pump Housing

17. Install the charge relief poppet and spring into the center section and tighten the plug (Fig. 3–145).

B–05380

Fig. 3–145 Installing Poppet & Spring

18. Install the high pressure relief replenishing valves and tighten the plug (Fig. 3–146).

19. Install the hydraulic pump on the hydrostaticpump on the hydrostatic pump assembly (See Paragraph 2–4.6, Page 2–15).

98 of 256

Revised June 94

–3–28–

B–05379

Fig. 3–146 Installing Valves 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

15. Install the coupling into the center section on the shaft of the pump (Fig. 3–143).

20. Install the port block on the hydraulic pump (See Paragraph 3–5.2).

21. Install the coupler assembly on the shaft of the hydrostatic pump (Fig. 3–147) and tighten the bolt to 25–28 ft.–lbs. (34–38 Nm) torque.

B–02894

Fig. 3–147 Installing Coupler Assembly

Dealer Copy -- Not for Resale

22. Install the steering linkage on the hydrostatic pump (See Paragraph 3–4.4).

3–7.8 Installing the Hydrostatic Pumps

B–05378

1. Put the hydrostatic pump assembly into the loader (Fig. 3–148), slide the pump assembly into the engine coupler.

Fig. 3–148 Installing Hydrostatic Pump Assembly

2. Install the bolts at the rear of the hydrostatic pump and tighten to 65–70 ft.–lbs. (88–95 Nm) torque (Fig. 3–149).

3. Install the front mounting bolts and tighten to 65–70 ft.–lbs.

(88–95 Nm) torque (Fig. 3–150).

99 of 256

B–05377

Fig. 3–149 Tighten the Rear bolts –3–29–

B–05376

Fig. 3–150 Tighten the Front Bolts 540, 543 Loader Service Manual

4. Install the high pressure hoses and tighten (Fig. 3–151 & 3–152).

5. Install the hoses on the hydraulic pump and the port block (Fig. 3–153).

6. Install the steering linkage at the pintle arms and the steering levers (Fig. 3–154 & 3–155).

B–05375

B–05373

Fig. 3–151 Installing High Pressure Hoses

Fig. 3–152 Installing High Pressure Hoses

7. Install the side shields.

9. Add fluid to the hydraulic/hydrostatic reservoir (See Section 8 for the correct fluid).

B–05374

10. Before you start the engine on the loader (See Paragraph 3–7.9 for the correct start–up procedure).

Fig. 3–153 Installing Hoses

11. Adjust the steering linkage (See Paragraph 3–4.1).

12. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

13. Remove the jackstands from under the loader frame.

3–7.9 Hydrostatic Pump Start–Up Procedure 1. Make sure all the hoses and tubelines are tight.

2. Check the hydraulic/hydrostatic reservoir, make sure the fluid level is correct.

3. Put the steering levers in the neutral position.

100 of 256

B–05330

Fig. 3–154 Installing Steering Linkage –3–30–

B–05348

Fig. 3–155 Installing Steering Linkage 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

8. Install the front panel.

4. Start the engine and run at a slow RPM. The charge pump must immediately pick up fluid and fill the system. If there is no sign of a fill in 30 seconds, stop the engine and check for the cause.

5. After the system is full, at a slow rate move the steering levers into forward position. Operate the system at a slow rate with no load until the system is at normal operation.

6. Stop the engine. Check the reservoir. Add fluid as needed.

7. Check all the tubelines and hoses to make sure there are no leaks.

8. Go back to Step 11 of installing the Hydrostatic Pump.

Dealer Copy -- Not for Resale

NOTE: The Oil Cooler Removal and Installation is located in the Hydraulic Section, Paragraph 2–8.

101 of 256

–3–31–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 102 of 256

–3–32–

540, 543 Loader Service Manual

DRIVE SYSTEM Paragraph Number 4–3 4–1 4–4 4–2

AXLES & BEARINGS . . . . . . . . . . . . . . . . .

BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAINCASE FLUID . . . . . . . . . . . . . . . . . .

FINAL DRIVE CHAINS . . . . . . . . . . . . . . . .

Page Number 4–7 4–1 4–10 4–5

Dealer Copy -- Not for Resale

DRIVE SYSTEM

WARNING

103 of 256

DO NOT service the Bobcat loader without instructions or taking the necessary safety precautions.

Before working on the loader , see the warnings and instructions at the beginning of this Service Manual.

After making the repair or adjustment, always check the function of the loader . Failure to obey warnings may cause injury or death.

–4––1–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 104 of 256

–4–0–

540, 543 Loader Service Manual

4 DRIVE SYSTEM 4–1 BRAKES

Always stop the engine and engage the parking brake before you leave the operator’s seat.

2 1/4” (6,35 mm)

1 A–02414R

Fig. 4–1 Brake Pedal Adjustment

B–05181

Fig. 4–2 Pedal Linkage

4–1.1 Parking Brake Adjustment

1. There must be 1/4” (6,35 mm) of movement under the bottom edge (heel) of the brake pedal (Fig. 4–1). This is done by first loosening the jam nut (Fig. 4–2, Item 1) and then turning the nut on the end of the linkage rod (Fig. 4–2, Item 2). The brake pucks must make contact with thebrake discs when the pedal is moved 1/4” (6,35 mm), but not be fully engaged.

2. If the adjustment can not be obtained by turning the nut (Fig. 4–2, Item 2), the brake lever must be removed from the cam pin.

Dealer Copy -- Not for Resale

When the brakes are in good condition and adjusted correctly, they will keep the loader from moving when in the parked position.

B–05188

Fig. 4–3 Removing Brake Lever 3. The hydrostatic pumps may have to be removed or lifted to getto the brake lever for easier removal.

4. Loosen the bolt on the brake lever. Do not remove the bolt.

5. Using pry bars and hammer, hit the bolt until the brake lever is loose from the cam pin (Fig. 4–3).

6. Remove the bolt and brake lever and turn the cam pin counterclockwise until the brake pucks make contact with the brake discs.

7. Install the brake lever and bolt. Tighten the bolt to 65–70 ft.–lbs. (88–95 Nm) torque.

8. Install or lower the hydrostatic pumps.

9. Adjust the parking brake as outlined in step 1.

4–1.2 Parking Brake Removal 1. Raise the Operator Guard (See Paragraph 5–5.1, Page 5–1).

B–5210

2. Remove the front panel (Fig. 4–4).

105 of 256

Fig. 4–4 Removing Front Panel –4–1–

540, 543 Loader Service Manual

3. Remove the steering levers (See Paragraph 3–3.1, Page 3–3).

4. Remove the hydrostatic pumps (See Paragraph 3–7.4, Page 3–20).

B–05171

Fig. 4–5 Removing Brake Pedal

B–05148

Fig. 4–6 Removing Spring

5. Remove the brake linkage from the pedal.

Dealer Copy -- Not for Resale

6. Remove the brake pedal (Fig. 4–5).

7. Remove the brake lever spring (Fig. 4–6).

8. Remove the bolts from the transmission covers (Fig. 4–7 & 4–8).

B–05151

IMPORTANT

Fig. 4–7 Removing Cover Bolts

B–05149

Fig. 4–8 Removing Cover Bolts

Be careful not to cause damage to the gaskets.

2”

3/8”

9. Using a pry bar , loosen the transmission covers (Fig. 4–9) and remove the covers.

10. Install the brake disc tool (Fig. 4–10) on the sprocket of the hydrostatic motor.

106 of 256

1–3/4”

9–1/2” B–05184

Fig. 4–9 Removing Covers –4–2–

B–03027

Fig. 4–10 Special Tool 540, 543 Loader Service Manual

11. Loosen the bolt on the hydrostatic motor (Fig. 4–1 1).

Remove the disc tool.

Lobe

Washer

12. Turn the retainer washer (Fig. 4–12) so that the brake disc can be removed from the sprocket (Fig. 4–13).

13. Remove the bolt from the brake lever (Fig. 4–14) and remove the brake lever.

B–05217

Fig. 4–11 Loosening Sprocket Bolt

Brake Disc

B–03021

Fig. 4–12 Retainer Washer Alignment

14. Remove the brake block from the transmission cover (Fig. 4–15).

Dealer Copy -- Not for Resale

15. Remove the brake pucks (Fig. 4–16) from the brake block.

B–05196

4–1.3 Parking Brake Inspection

Fig. 4–13 Removing Disc

1. Check the brake disc for damage. Replace discs as needed. DO NOT grind the discs.

2. Check the pucks for wear or damage. The pucks can be turned 180° and the smooth side used again.

B–05174

3. Check for a good fit between the pucks and the bore in the block. They must be free to slide in the block.

Fig. 4–14 Brake Lever Bolt

4–1.4 Parking Brake Installation 1. Install the brake pucks and retainers into the brake block (Fig. 4–16). Install the first and the last puck into the puck retainer.

107 of 256

B–05179

Fig. 4–15 Brake Block Bolts –4–3–

B–05146

Fig. 4–16 Removing Brake Puck 540, 543 Loader Service Manual

2. Install the o–ring on the cam pin (Fig. 4–17). Install the cam pin into the brake block. Make alignment of the puck retainer and the cam pin.

3. Put a bead of silicone rubber sealant on the brake block (Fig. 4–18).

B–05208

Fig. 4–17 Installing O–ring & Cam Pin

B–05206

Fig. 4–18 Silicone on Brake Block

Dealer Copy -- Not for Resale

4. Install the transmission cover on the brake block (Fig. 4–19).

5. Put loctite on the bolts and tighten the bolts to 65–70 ft.–lbs. (88–95 Nm) torque (Fig. 4–20).

B–05204

6. Install the brake discs on the sprocket teeth (Fig. 4–21).

Fig. 4–19 Installing Cover

B–05186

Fig. 4–20 Tighten Brake Block Bolts

Lobe

7. Turn the retainer washer so the lobes will hold the disc on the sprocket (Fig. 4–22).

8. Install the disc special tool and tighten the sprocket bolt to 260–300 ft.–lbs. (352–407 Nm) torque.

108 of 256

Washer

B–05196

Fig. 4–21 Installing Brake Discs –4–4–

Brake Disc

B–03022

Fig. 4–22 Retainer Washer Alignment 540, 543 Loader Service Manual

9. Put the transmission cover/brake assembly over the brake discs (Fig. 4–23).

10. Align the brake discs so they are centered between the brake pucks.

11. Align the holes in the transmission cover and gasket. Install the bolts and tighten to 16–20 ft.–lbs. (22–27 Nm) torque.

12. Install the brake lever on the cam pin. Pull the brake lever to put the brake pucks against the discs and install the brake lever bolt in the brake lever and tighten to 65–70 ft.–lbs. (88–95 Nm) torque.

13. Install the brake linkage, spring and brake pedal.

14. Make adjustment to the parking brake (See Paragraph 4–1.1).

B–05213

Fig. 4–23 Installing Brake Assembly 15. Install the hydraulic pumps (See Paragraph 3–7.8, Page 3–29).

Dealer Copy -- Not for Resale

16. Install the steering levers (See Paragraph 3–3.3, Page 3–4).

17. Install the front panel.

18. Lower the operator guard (See Paragraph 5–1.2, page 5–1).

4–2 FINAL DRIVE CHAINS The final drive uses the hydrostatic motors and the roller chains. The chains do not have connector links.

4–2.1 Remove the Drive Chain(s)

IMPORTANT

Lift the loader and put blocks under the frame so that there is no danger of the loader falling and causing personal injury.

The tools listed will be needed to do the following procedure: MEL–1045 Chain Breaker 1. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

2. Remove the front panel (Fig. 4–24).

3. Remove the steering levers (See Paragraph 3–3.1, Page 3–3).

109 of 256

–4–5–

B–05210

Fig. 4–24 Removing Front Panel 540, 543 Loader Service Manual

4. Remove the hydrostatic pumps (See Paragraph 3–7.4, Page 3–20).

5. Remove the transmission covers and brake assembly (See Paragraph 4–1.2).

6. Remove the fluid from the chaincase (See Paragraph 4–4.1).

7. Check the drive chain for the connector link. If there is no connector link, make separation of the drive chain at any link.

8. Using the chain breaker tool, separate the chain.

9. Remove the drive chain(s).

B–04663

Fig. 4–25 Installing Drive Chain

4–2.2 Installing the Drive Chain(s) The tools listed will be needed to do the following procedure:

1. Remove the axle and sprocket (See Paragraph 4–3.1) where the new drive chain will be installed.

2. Make sure the chaincase is clean.

3. Put the drive chain into the chaincase. Put it over the sprocket of the hydrostatic motor and pull the ends out and above the chaincase.

B–04658

Fig. 4–26 Installing Bar

4. Mark the connector link plate and install the connector link into the drive chain (Fig. 4–25).

5. Put a flat bar under the drive chain and across the chaincase (Fig. 4–26) and clamp to the chaincase.

6. Put the plate on the connector link (Fig. 4–27) and start it into the correct position with a pliers.

7. Install the chain link press tool (Fig. 4–28) and clamp it to the flat bar.

8. Put a torque wrench on the chain link press tool (Fig. 4–29) and tighten to 180 ft.–lbs. (244 Nm) torque to press the connector plate into position.

B–04664

Fig. 4–27 Installing Link Plate

9. Remove the chain link press tool and the flat bar from the chain.

10. Install the axle sprocket into the chaincase and position is in line for the axle installation.

11. Install the axle (See Paragraph 4–3.2).

12. Install the transmission cover/brake assembly (See Paragraph 4–1.4).

13. Install the hydrostatic pumps (See Paragraph 3–7.8, Page 3–29).

110 of 256

B–04659

Fig. 4–28 Installing Chain Link Tool –4–6–

B–04657

Fig. 4–29 Pressing Connector Link 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

MEL–1037 Chain Link Press Tool

14. Install the steering levers (See Paragraph 3–3.3, Page 3–4).

15. Install the front panel.

16. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

17. Remove the jackstands from under the loader frame.

18. Add fluid to the chaincase (See Section 8 for the correct fluid).

4–3 AXLES AND BEARINGS Removal, assembly and installation is the same for all four (4) axles on the loader .

Dealer Copy -- Not for Resale

WARNING

Lift the loader and put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

4–3.1 Removing Axle(s) and Bearings The tools listed will be needed to do the following procedure: Slide Hammer (Purchased Locally) 1. Remove the tire and wheel assembly.

2. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

3. Remove the front panel.

4. Remove the steering levers (See Paragraph 3–3.1, Page 3–1).

5. Remove the hydrostatic pumps (See Paragraph 3–7.4, Page 3–20).

B–03992

Fig. 4–30 Sprocket Bolt 6. Remove the transmission cover/brake assembly (See Paragraph 4–1.2).

7. Remove the final drive chain (See Paragraph 4–2.1).

8. Remove the bolt and washer from the end of the axle (Fig. 4–30).

9. Use a slide hammer to remove the axle from the inner bearing and the sprocket (Fig. 4–31).

111 of 256

B–03980

Fig. 4–31 Removing the Axle –4–7–

540, 543 Loader Service Manual

10. Move the sprocket away from the axle tube

11. Using a long punch, removethe inside bearing cup (Fig. 4–32).

B–02840

Fig. 4–32 Removing Bearing Cup

B–03987

13. Use a puller (Fig. 4–34) to remove the outer bearing from the axle.

14. Clean and check all the partsfor wear or damage. Replace the parts as needed.

Fig. 4–33 Removing Bearing Cup

Bearing

B–02813

Fig. 4–34 Removing Outer Bearing

2

3

4–3.2 Assembly of the Axle

1. Lubricate the axle seal and install the seal on the axle (Fig. 4–35, Item 1) with the open side of the seal toward the chaincase.

112 of 256

1

C–02659

Fig. 4–35 Axle Assembly –4–8–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

12. Using a bearing puller tool and slide hammer (Fig. 4–33) remove the outer bearing cup.

2. Using an arbor install the outer bearing on the axle (Fig. 4–36).

Press only on the inner race of the bearing (Fig. 4–37). Thiswill also position the seal in its location.

4–3.3 Axle and Installation

Bearing

Oil Seal

Bearing

The tools listed will be needed to do the following procedure: MEL–1051 Axle Seal Tool MEL–1202A Axle Bearing Race Set

B–03981

Fig. 4–36 Installing Outer Bearing

B–03984

Fig. 4–37 Installing Outer Bearing

1. Using a bushing driver , install the outer bearing cup (Fig. 4–38).

3. Put the sprocket into the chaincase.

NOTE: The wide part of the sprocket hub goes toward the inside for the front axles and toward the outside for the rear axles.

B–03982

Fig. 4–38 Installing Bearing Cup

Dealer Copy -- Not for Resale

2. Position the inner bearing cup inside the chaincase in the axle tube. Use a long bolt and washers and pull the bearing cup into the correct position.

B–02770

Fig. 4–39 Installing Inner Halves of Tool

4. Install the axle assembly into the axle housing tube.

NOTE: Pack all the bearings with grease before installation.

5. Install the inner halves of the installation tool behind the outer axle seal (Fig. 4–39).

6. Install the outer halves of the installation tool on the inner halves of the tool (Fig. 4–40).

B–02774

Fig. 4–40 Installing Outer Halves of Tool

7. Install the spring on the installation tool (Fig. 4–41).

8. Push inward and install the inner bearing.

9. Put the sprocket on the end of the axle.

10. Put the installation tool in contact with the axle housing tube. Install the washer and bolt (Fig. 4–35, Items 2 & 3) and pull the axle to the inside to prevent damage to the bearing and seal.

11. Using a large hammer, hit the axle hub until the axle is installed.

B–02772

Fig. 4–41 Installing Spring

12. Remove the spring from the installation tool.

113 of 256

Revised Nov. 89

–4–9–

540, 543 Loader Service Manual

13. Remove the outer halves of the installation tool from the inner halves.

14. Remove the inner halves of the installation tool from the axle.

15. Make sure the sprocket is installed correctly on the axle.

Put loctite on the bolt and tighten the bolt on the end of the axle to 300–330 ft.–lbs.

(407–448 Nm) torque. Check the axle end play . It must be between 0.00–0.10” (0,000–0,25 mm). If not, replace the washer (Fig. 4–35, Item 3) to get the correct end play.

16. Install the final drive chain (See Paragraph 4–2.2).

B–05202

Fig. 4–42 Removing Chaincase Fluid

17. Install the transmission cover/brake assembly (See Paragraph 4–1.4).

Dealer Copy -- Not for Resale

18. Install the steering levers (See Paragraph 3–3.3, Page 3–4).

19. Install the front panel.

20. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

21. Remove the jackstands from under the loader frame.

4–4 CHAINCASE FLUID 4–4.1 Replacing Chaincase Fluid 1. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

2. Remove the brake linkage and brake pedal (See Paragraph 4–1.2).

3. Remove the front transmission cover.

B–03988

4. Use a pump (Fig. 4–42) to remove the fluid from the chaincase.

Fig. 4–43 Cleaning Chaincase

5. Use clean rags to remove any fluid that the pump did not remove and to clean the chaincase (Fig. 4–43).

6. Use only recommended replacement fluid (See Section 8 for the correct fluid) to fill the chaincase with 16 qts. (15 L) of fluid.

7. Install the front transmission cover.

8. Install the brake pedal and linkage (See Paragraph 4–1.4).

9. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

114 of 256

Revised Nov. 89

–4–10–

540, 543 Loader Service Manual

MAIN FRAME Paragraph Number 5–3 5–5 5–2 5–1 5–4

BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . .

LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATOR GUARD . . . . . . . . . . . . . . . . .

REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . .

Page Number 5–5 5–11 5–3 5–1 5–9

Dealer Copy -- Not for Resale

MAIN FRAME

WARNING

115 of 256

DO NOT service the Bobcat loader without instructions or taking the necessary safety precautions.

Before working on the loader , see the warnings and instructions at the beginning of this Service Manual.

After making the repair or adjustment, always check the function of the loader . Failure to obey warnings may cause injury or death.

–5––1–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 116 of 256

–5–0–

540, 543 Loader Service Manual

5 MAIN FRAME 5–1 OPERATOR GUARD 5–1.1 Raising the Operator Guard 1. Stop the loader on a level surface.

2. Put the lift arms all the way down or hold the lift arms up with a LIFT ARM STOP. The LIFT ARM STOP must be installed by a second person while the operator is in the operator’s seat.

3. Stop the engine, engage the brake. Disconnect the wire harness behind the seat (Fig. 5–1).

Fig. 5–1 Wire Harness Connectors

When raising the operator guard or working on the loader , put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

4. Put jackstands or blocks under the rear corners of the Bobcat loader to keep the loader from tipping backwards.

C–02599

5. Remove the two (2) bolt assemblies (including washers) at the frontcorners of the operator guard (Fig. 5–2).

Fig. 5–2 Operator Guard Bolts

6. Two (2) persons are needed to lift the operator guard. A surfaces when lifting the operator guard.

CORRECT

void slippery

Dealer Copy -- Not for Resale

WARNING

B–04696

7. Stand on the ground, one person on each side and lift the operator guard using the grab handles and the bottom of the operator guard (Fig. 5–3).

8. Lift slowly until the operator guard is all the way up. The operator guard will lock in this position (See Paragraph 5–1.3 and install the jumper start switch as needed).

5–1.2 Lowering the Operator Guard

B–03846

1. Stop the engine and remove the jumper start switch.

2. Two (2) persons are needed to lower the operator guard. A void slippery surfaces when lowering the operator guard.

Fig. 5–3 Raising the Guard

WRONG

3. Stand on the ground, one person on each side and pull down on the operator guard until it contacts the lock mechanism.

WARNING

If the lift arms are raised, reach for the ring on the cable from under the lift cylinder. DO NOT reach between the lift arms and the lift cylinder.

B–03845

Fig. 5–4 Raising the Guard 117 of 256

–5–1–

540, 543 Loader Service Manual

4. Pull the ring on the cable (Fig. 5–5) while the second person lifts the operator guard a small amount until the lock mechanism is released.

5. Both persons must slowly lower the operator guard by holding the bottom of the operator guard and the grab handles (Fig. 5–3).

6. Install the two (2) nuts and washers (Fig. 5–2). T ighten the nuts to 40–50 ft.–lbs. (54–69 Nm) torque.

7. Connect the wiring harness behind the seat (Fig. 5–1).

8. Remove the LIFT ARM STOP while the second person is in the operator seat.

B–04039

Fig. 5–5 Operator Guard Cable

5–1.3 Jumper Start Switch The tool listed will be needed to do the following procedure:

The short wire harness assembly is required when the operator guard is in the raised position for service and the serviceman needs to start theengine. The wire harness connectors separate when the operator guard is tilted back. Install the short wire harness (Fig. 5–6) into the engine wire harness of the loader . This jumper start switch is required when the serviceman is adjusting the steering linkage, checking the charge pressure and making hydraulic/hydrostatic pump tests.

B–04459

Fig. 5–6 Jumper Start Switch

5–1.4 Removing the Operator Guard

When raising the operator guard or working on the loader, put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

1. Stop the engine.

2. Raise the operator guard (See Paragraph 5–1.1).

3. Fasten a chain hoist to the operator guard as shown in figure 5–7).

4. Remove the bolts and remove the spring blocks that hold the springs in position (Fig. 5–8).

118 of 256

C–02630

Fig. 5–7 Installing Chain Hoist –5–2–

B–04542

Fig. 5–8 Bolt & Spring Block 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

MEL–1138 Jumper Start Switch

5. Remove the nuts from the pivot bolts (Fig. 5–9).

6. With a chain hoist tight, using a punch, remove the pivot bolts from the operator guard pivot brackets (Fig. 5–10).

7. Using a pry bar, pry the springs out of the operator guard (Fig. 5–11).

8. Remove the operator guard with the chain hoist.

5–1.5 Installing the Operator Guard 1. Raise the operator guard, with a chain hoist, over the loader.

2. Make alignment of the spring ends and install them in the operator guard (Fig. 5–11).

3. Lower the chain hoist until the pivot bracket holes are in alignment.

4. Install the pivot bolts in the pivot brackets.

B–04054

5. Install the nuts and tighten to 25–35 ft.–lbs. (34–47 Nm) torque (Fig. 5–9).

Fig. 5–9 Removing the Nut

6. Install the spring blocks. Install the bolts in the spring blocks and tighten to 65–70 ft.–lbs. (88–95 Nm) torque.

Dealer Copy -- Not for Resale

7. Remove the chain hoist from the operator guard.

8. Lower the operator guard (See Paragraph 5–1.2).

9. Remove the jackstands from under the loader frame.

5–2 LIFT ARMS 5–2.1 Removing the Lift Arms

B–04047

Fig. 5–10 Removing the Bolt

When raising the operator guard or working on the loader, put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

1. Stop the engine, activate the hydraulic controls to release all the hydraulic pressure.

2. Remove the Bob–Tach from the lift arms (See Paragraph 5–3.1).

3. Fasten a chain hoist to the lift arms as shown in figure 5–12.

119 of 256

B–04057

Fig. 5–11 Guard Spring –5–3–

B–02801

Fig. 5–12 Installing the Chain Hoist 540, 543 Loader Service Manual

4. Put a floor jack under the lift arms (Fig. 5–13).

5. Raise the lift arms, with the floor jack, until the pivot pins in the rod end of the lift cylinders can be removed.

6. Remove the locknut and bolt from the rod end pivot pins (Fig. 5–14) (Both sides).

B–04543

Fig. 5–13 Lifting Lift Arms with FloorJack

B–04392

Fig. 5– Locknut & Bolts

Dealer Copy -- Not for Resale

7. Remove the pivot pins (Fig. 5–15). Be careful when removing the pivot pins at the lift cylinder. Put a support under the cylinder to keep it from falling when the pins are removed.

8. Lower the lift arms and remove the floor jack.

9. Remove the locknut and bolt (Fig. 5–16) (Both sides) from the lift arm pivot pin.

10. Tighten the chain hoist.

Remove the pivot pins (Fig. 5–17) from the lift arms.

B–04393

11. Raise the lift arms, with the chain hoist and remove the lift arms from the loader.

Fig. 5–15 Removing Rod End Pin

5–2.2 Installing the Lift Arms 1. With a chain hoist, position the lift arms on the loader and make alignment of the pivot pin holes in the lift arms and main frame.

2. Install the pivot pins in the main frame and the lift arms.

3. Install the bolt and locknut and tighten to 18–20 ft.–lbs. (24–27 Nm) torque (Fig. 5–16).

120 of 256

–5–4–

B–04544

Fig. 5–16 Locknut & Bolt 540, 543 Loader Service Manual

4. Remove the chain hoist chains from the lift arms.

and

5. Install the rod end of the cylinder in the lift arms.

lift

6. Install the pivot pin in the lift cylinder.

7. Install the bolt and the locknut in the pivot pin and tighten to 18–20 ft.–lbs. (24–27 Nm) torque (Fig. 5–14).

B–04545

Fig. 5–17 Removing Pivot Pins from the Lift Arms 8. Install the Bob–Tach on the lift arms (See Paragraph 5–3.4).

from

Dealer Copy -- Not for Resale

9. Remove the jackstands under the loader frame.

5–3 BOB–TACH 5–3.1 Removing the Bob–Tach 1. Start the engine. Tilt the Bob–Tach forward until the front edge of the Bob–Tach is on the floor (Fig. 5–18).

B–05103

Fig. 5–18 Removing the Bob–Tach

B–05104

2. Stop the engine. Activate the hydraulic controls to release the hydraulic pressure from the system.

Fig. 5–19 Locknut & Bolt

3. Remove the locknut and bolt at the rod end of the tilt cylinder (Fig. 5–19).

4. Remove the pivot pin (Fig. 5–20) from the tilt cylinder rod end.

121 of 256

B–05105

Fig. 5–20 Removing the Pivot Pin –5–5–

540, 543 Loader Service Manual

5. Loosen the bolt 1–1 1/2 turns (Do not remove) at the Bob–Tach pivot pin (Fig. 5–21) (Both sides).

6. Remove the grease fitting at the pivot pin (Fig. 5–22).

NOTE: The grease fitting at the pivot pin must be removed, because the grease can cause a lock and the pivot pin cannot be pushed into the Bob–Tach frame.

B–05106

Fig. 5–21 Pivot Pin Bolt

B–05107

Fig. 5–22 Grease Fitting

8. Remove the bolt and use a punch to push the pivot pin into the Bob–Tach frame.

Dealer Copy -- Not for Resale

7. Hit the bolt, witha hammer (Fig. 5–23) to start the pivot pin into the Bob–Tach frame. This will break the pin loose from the tapered seat.

B–5109

Fig. 5–23 Removing Pivot Pin

9. Remove the Bob–Tach from the lift arms.

B–04871

Fig. 5–24 Removing the Pivot Pin

5–3.2 Disassembly of the Bob–Tach

1. Put the Bob–Tach on the work bench.

2. Remove the Bob–T ach pivot pins (Fig. 5–24).

3. Remove the bolt at the Bob–Tach lever (Fig. 5–25).

4. Use a punch and hammer to remove the wedge and lever assembly from the frame (Fig. 5–26).

122 of 256

B–05111

Fig. 5–25 Removing the Lever Bolt –5–6–

B–05112

Fig. 5–26 Removing Wedge Assembly 540, 543 Loader Service Manual

5. Put the wedge and lever assembly in the vise. Remove the bolt from the lever (Fig. 5–27).

6. Remove the block from the wedge bolt (Fig. 5–28).

7. Remove the nut (Fig. 5–29) and remove the spring from the bolt.

B–04553

Fig. 5–27 Lever Bolt

B–04554

Fig. 5–28 Wedge Block

8. Remove the plastic guides from the Bob–Tach frame (Fig. 5–30).

B–04556

5–3.3 Assembly of the Bob–Tach

Fig. 5–29 Removing the Nut

Dealer Copy -- Not for Resale

9. Clean and inspect all the parts for wear and damage. Replace the parts as needed.

B–04875

Fig. 5–30 Removing Plastic Guides

1. Install the spring on the wedge bolt. Install the nut (Fig. 5–31).

6.09–6.21” (155–158 mm) 2. Install the block on the wedge bolt. Turn the block down until there is 6.09–6.21” (155–158 mm) from the center of the lever bolt hole to the top ofthe wedge where the spring seats (Fig. 5–32).

B–04556

Fig. 5–31 Installing the Spring

B–04554

Fig. 5–32 Installing the Block

3. Tighten the nut to 65–70 ft.–lbs.

(88–95 Nm) torque to lock the block into position.

4. Install the lever and bolt and tighten the bolt to 25–28ft.–lbs.

(34–38 Nm) torque (Fig. 5–33).

5. Install the new plastic guides in the Bob–Tach frame (Fig. 5–34).

123 of 256

B–04557

Fig. 5–33 Tightening the Lever Bolt –5–7–

B–04875

Fig. 5–34 Installing Plastic Guides 540, 543 Loader Service Manual

6. Using a punch and hammer , install the wedges and lever assembly in the Bob–T ach frame (Fig. 5–35).

7. Install the spring behind the lever. Install the bolt and tighten to 25–28 ft.–lbs. (34–38 Nm) torque (Fig. 5–36).

B–05111

8. Install the pivot pin in the Bob–Tach frame (Fig. 5–37), the tapered area facing out.

Fig. 5–36 Tightening Lever Bolt

B–05112

Fig. 5–35 Installing Wedge & Lever Assy.

5 5–3.4 Installing the Bob–Tach

2. Using a punch, push the pivot pin into the lift arms (Fig. 5–38) from the grease fitting hole.

B–04871

Fig. 5–37 Installing Pivot Pin

3. Install the bolt and washer into the pivot pin and tighten to 125–140 ft.–lbs. (170–190 Nm) torque (Fig. 5–39).

4. Install the grease fittings and tighten (Fig. 5–40).

B–04889

Fig. 5–38 Installing Pivot Pin 5. Lubricate the pivot pins with grease.

6. Put the floor jack under the Bob–Tach frame.

7. Lift the Bob–Tach frame, with the floor jack, until the tilt cylinder rod end hole is in alignment with the holes in the Bob–Tach frame.

124 of 256 Revised Nov. 89

B–05106

Fig. 5–39 Tightening the Bolt –5–8–

B–05107

Fig. 5–40 Installing Grease Fitting 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

1. Put the Bob–Tach between the lift arms.

8. Install the rod end pin in the Bob–Tach frame (Fig. 5–41).

9. Install the bolt and locknut and tighten (Fig. 5–42). Lubricate the grease fittings.

B–05113

5–4 REAR DOOR

Fig. 5–41 Installing Pivot Pin

5–4.1 Removing the Rear Door (Early Model) 1. Open the rear door.

Dealer Copy -- Not for Resale

2. Remove the retainer bolt at the bottom hinge on the door (Fig. 5–43).

B–05104

3. Lift the rear door from the loader main frame (Fig. 5–44).

Fig. 5–42 Tightening the Bolt

NOTE: On the 540 loader the oil cooler hoses will have to be removed (See Paragraph 2–8.1, Page 2–24).

B–05114

Fig. 5–43 Door Retainer Bolt (Early)

Keep the rear door closed except for service. Make sure you close the door and fasten the latch tightly before operating the Bobcat loader.

5–4.2 Removing the Rear Door (Later Models) 1. Open the rear door.

125 of 256

B–05115

Fig. 5–44 Rear Door (Early) –5–9–

540, 543 Loader Service Manual

2. Install a chain hoist on the door (Fig. 5–45).

rear

3. Remove the hinge pins (Fig. 5–46).

4. Remove the rear door.

5–4.3 Installing the Rear Door 1. Install the rear door on the loader.

2. Make alignment of the hinges and hinge bracket and install thehinge pins.

B–04568

Fig. 5–45 Installing the Chain Hoist (Later Models)

Dealer Copy -- Not for Resale

3. Remove the chain hoist.

5–4.4 Adjusting the Rear Door Latch 1. Loosen the locknut at the latch bolt (Fig. 5–47).

2. Turn the latch bolt (Fig. 5–48) in or out to get the correct adjustment.

3. Close the rear door.

4. The rear door must contact the main frame at the bottom and top with the lever in the position as shown in figure 5–49.

B–04131

Fig. 5–46 Hinge Pins

B–04101

Fig. 5–47 Door Latch Nut

5. It will take about 50 lbs. of pressure to push the lever down into the locked position if the rear door is adjusted correctly.

Keep the rear door closed except for service. Make sure you close the door and fasten the latch tightly before operating the Bobcat loader.

B–04099

B–04571

Fig. 5–48 Latch Bolt 126 of 256

–5–10–

Fig. 5–49 Closing Rear Door 540, 543 Loader Service Manual

5–5 FUEL TANK 5–5.1 Removing the Fuel Tank 1. Raise the lift arms and install a lift arm stop (See Paragraph 1–1 1, Page 1–16). Stop the engine.

2. Raise the operator guard Paragraph 5–1.1).

(See

3. Disconnect the wire from the connector in the operator guard (Fig. 5–50).

B–04886

4. Put the wire in the tank area (Fig. 5–51).

Fig. 5–50 Disconnecting Sender Wire

B–04882

Fig. 5–51 Moving Sender Wire

Dealer Copy -- Not for Resale

5. Remove the fuel line at the tank (Fig. 5–52).

6. Remove the nut holding the strap (Fig. 5–53).

7. Remove the fuel tank (Fig. 5–54).

B–04877

5–5.2 Installing the Fuel Tank

Fig. 5–52 Disconnecting Fuel Line

B–04894

Fig. 5–53 Removing the Nut

1. Put the fuel tank in its correct location.

2. Connect the strap to the bolt and install the nuts and tighten (Fig. 5–53).

3. Connect the fuel line at the tank.

4. Connect the sender wire (Fig. 5–50).

5. Lower the operator guard (See Paragraph 5–1.2).

6. Remove the lift arm stop (See Paragraph 1–11, Page 1–16) and lower the lift arms.

127 of 256

–5–11–

B–04895

Fig. 5–54 Removing Fuel Tank 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 128 of 256

–5–12–

540, 543 Loader Service Manual

ALTERNATOR SYSTEM (540) . . . . . . . . .

ALTERNATOR SYSTEM (543) . . . . . . . . .

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM INFORMATION STARTER (540) . . . . . . . . . . . . . . . . . . . . . .

STARTER (543) . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING . . . . . . . . . . . . . . . .

WIRE HARNESS FOR THE ENGINE . . .

WIRE HARNESS FOR THE OPERATOR GUARD . . . . . . . . . . . . . . . .

Paragraph Number 6–6 6–7 6–3 6–2 6–8 6–9 6–1 6–5

Page Number 6–6 6–6 6–3 6–2 6–11 6–12 6–1 6–5

6–4

6–4

ELECTRICAL SYSTEM

WARNING

129 of 256

Dealer Copy -- Not for Resale

ELECTRICAL SYSTEM

DO NOT service the Bobcat loader without instructions or taking the necessary safety precautions.

Before working on the loader , see the warnings and instructions at the beginning of this Service Manual.

After making the repair or adjustment, always check the function of the loader . Failure to obey warnings may cause injury or death.

–6––1–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 130 of 256

–6–0–

540, 543 Loader Service Manual

131 of 256

Dealer Copy -- Not for Resale

132 of 256

Dealer Copy -- Not for Resale

133 of 256

Dealer Copy -- Not for Resale

134 of 256

Dealer Copy -- Not for Resale

135 of 256

Dealer Copy -- Not for Resale

136 of 256

Dealer Copy -- Not for Resale

137 of 256

Dealer Copy -- Not for Resale

138 of 256

Dealer Copy -- Not for Resale

6 ELECTRICAL SYSTEM 6–1 TROUBLESHOOTING The following troubleshooting chart is provided for assistance in locating and correcting problems. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure to follow instructions can cause injury or death.

PROBLEM

CAUSE

Battery loses charge.

1, 2, 3, 4, 5,

Alternator will not charge.

1, 2, 5

Starter will not turn the engine.

2, 3, 4, 6, 7, 8, 9

KEY TO CORRECT THE CAUSE

139 of 256 Revised Oct. 98

1.

Alternator belt is loose or damaged.

2.

Battery connections are dirty or loose.

3.

Battery is defective.

4.

The ground is not correct in the electrical system.

5.

The alternator has a defect.

6.

Engine seizure.

7.

Starter has a defect.

8.

Wiring or solenoid has a defect.

9.

Fuse has a defect.

–6–1–

Dealer Copy -- Not for Resale

W–2003–0797

540, 543 Loader Service Manual

6–2 ELECTRICAL SYSTEM INFORMATION 6–2.1 Electrical Circuitry There are two (2) basic circuits in the electrical system of the loader: 1. Charging Circuit a. Alternator b. Internal Regulator c. Voltmeter d. Battery 2. Starting Circuit a. Starter b. Solenoids c. Battery The ignition switch must be turned “ON” to activate these circuits.

A–02740

Fig. 6–1 Battery Warning – Do Not Smoke Near the Battery

6–2.2 Safety Procedures for the Batteries

WARNING

Dealer Copy -- Not for Resale

Batteries contain acid which burns eyes and skin on contact. W ear goggles, protective clothing and rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

W–2065–1296

DO NOT remove the vent caps from the batterieswhile charging. The battery has a vent cap which will decrease the possibility of the battery being exploded by an external spark. Always disconnect the ground cable from the batteries before charging.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

When jumping from booster battery make final connection (negative) at engine frame.

WARNING

Do not jump start or charge a frozen or damaged battery. Warm battery to 60_F. (16_C) before connecting to a charger,. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging.

Battery gas can explode and cause serious injury.

W–2066–1296

140 of 256

Revised Oct. 98

–6–2–

540, 543 Loader Service Manual

6–2.3 Precautions for the Alternator 1. DO NOT reverse the battery connections. This is a negative ground system only.

2. Connect the battery correctly.

3. DO NOT polarize the alternator.

4. DO NOT ground any of the wires from the alternator.

Damage to the alternator can occur if:

B–05173

Fig. 6–2 Battery Cables (540)

1. Engine is operated with battery cables disconnected.

3. Extra battery cables connected wrong.

are

Dealer Copy -- Not for Resale

IMPORTANT

2. Cables are connected when using fast charger or when welding on the loader (Remove both cables from the battery and disconnect the alternator) (Always disconnect the ground cable first).

B–05157

6–3 BATTERY

Fig. 6–3 Battery Cables (543)

6–3.1 Removing the Battery The tools listed will be needed to do the following procedure: MEL–1069 Battery Terminal Puller 1. Stop the engine. Open the rear door.

2. Disconnect the cables from the battery (Fig. 6–2 & 6–3).

Always disconnect the negative cable first to prevent sparks.

3. Remove the nuts and bolts from the holddown clamps (Fig. 6–4 & 6–5) and remove the holddown clamp.

B–05175

B–05158

Fig. 6–4 Battery Holddown Clamps (540)

Fig. 6–5 Battery Holddown Clamps (543)

4. Remove the battery and battery bracket from the loader (Fig. 6–6 & 6–7).

B–05177

Fig. 6–6 Loader Battery (540) 141 of 256

Revised Oct. 98

–6–3–

B–05160

Fig. 6–7 Loader Battery (543) 540, 543 Loader Service Manual

6–3.3 Installing the Battery

2

1. Put the battery bracket in the loader and locate it in the correct position.

2. Install the battery into the battery bracket (Fig. 6–6 & 6–7).

1 3. Install the battery holddown clamps (Fig. 6–4 & 6–5) and tighten the nuts to 30–50 in.–lbs.

(3,4–5,7 Nm) torque.

B–04696

Fig. 6–8 Wire Harness Connector

4. Connect the positive cable first and tighten the clamp.

B–04491

5. Connect the negative cable and tighten the clamp.

Fig. 6–9 Wire Harness Clip

Dealer Copy -- Not for Resale

6. Close the rear door.

6–4 WIRE HARNESS FOR THE OPERATOR GUARD 6–4.1 Removing the Wire Harness for the Operator Guard 1. Open the rear door . Disconnect the negative cable from the battery.

2. Disconnect the wiring harness connector behind the seat (Fig. 6–8).

B–04504

Fig. 6–10 Rear Light

B–04497

Fig. 6–11 Harness Clip

3. Disconnect the connector at the fuel sender wires (Fig. 6–9, Item 1).

4. Remove the harness clip (Fig. 6–9, Item 2).

5. Remove the rear light from the mounting. Disconnect the wires from the rear light (Fig. 6–10).

6. Remove all the harness clips on the operator guard up to the dash panel (Fig. 6–11).

7. Remove the dash panel nuts and bolts (Fig. 6–12).

142 of 256

Revised Oct. 98

B–04498

Fig. 6–12 Dash Panel Bolts & Nuts –6–4–

540, 543 Loader Service Manual

8. Remove the front lights from the mounting. Disconnect the wires from the front lights (Fig. 6–13).

9. Pull the dash panel down and remove the wires for the front lights from the rubber grommets (Fig. 6–14).

10. Remove the dash panel from the loader and put it on the work bench.

Locate the new wiring harness along side the dash panel. Disconnect a wire from the dash panel, find the wire in the new wiring harness and connect it to the same location.

Also see the WIRING DIAGRAM at the front of the Electrical Section.

6–4.2 Installing the Wire Harness for the Operator Guard 1. After the new wiring harness is installed in the dash panel, make sure that all the terminals are tight.

B–04495

Fig. 6–13 Front Light

2. Install the dash panel in the loader.

4. Put the dash panel in the correct position. Install the bolts and nuts tighten.

Dealer Copy -- Not for Resale

3. Put the wires for the front lights through the rubber grommets (Fig. 6–14). and

5. Connect the wires to the front lights (Fig. 6–13). Install the front lights in the rubber mounting.

6. Install the harness clips along the side of the operator guard (Fig. 6–11).

7. Put the wires for the rear light through the rubber grommet and connect the wires to the rear light (Fig. 6–10).

B–04501

Fig. 6–14 Rubber Grommets 8. Connect the wires to the fuel sender (Fig. 6–9, Item 1).

9. Connect the wire harness connectors (Fig. 6–8).

10. Connect the negative cable to the battery.

11. Close the rear door.

6–5 WIRE HARNESS FOR THE ENGINE When installing a new wiring harness on the engine, locate the new wiring harness by the engine. Disconnect a wire from the engine (Example: oil pressure sender), find the wire in the new wiring harness and connect it to the same location.

Also use the WIRING DIAGRAM at the front of the Electrical Section.

143 of 256

–6–5–

540, 543 Loader Service Manual

6–6 ALTERNATOR SYSTEM (540) 6–6.1 Checking the A.C. Voltage

Lift the loader and put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

B–02906

Fig. 6–15 Checking A.C. Voltage

C–02336

Fig. 6–16 Removing Flywheel Nut

1. Disconnect the stator wires from the rectifier and connect them to the A.C. voltmeter (Fig. 6–15).

2. Start the engine and run at maximum RPM. 3. The voltage must be 28 or more volts. If the voltage is less than 20 volts @ 2500 RPM, replace the stator. If the voltage is over 20 volts the stator is good.

6–6.2 Replacement of the Stator 1. Remove housing.

B–02881

Fig. 6–18 Removing the Stator

the engine blower

2. Hold the flywheel with a piece of wood and remove the nut (Fig. 6–16).

3. Use a puller and remove the flywheel from the engine (Fig. 6–17).

4. Remove the bolts that hold the stator to the engine (Fig. 6–18).

C–02334

Fig. 6–17 Removing Flywheel

5. Install the new stator and tighten the bolts.

6. Install the flywheel and tighten the nut to 115 ft.–lbs. (156 Nm)torque.

7. Install the blower housing.

6–7 ALTERNATOR SYSTEM (543) 6–7.1 Belt Adjustment for Alternator

the

1. Stop the engine. Open the rear door.

2. Loosen the top bolt on the alternator mounting bracket (Fig. 6–19).

B–05162 B–05165

Fig. 6–19 Top Mounting Bolt 144 of 256

–6–6–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

Bolts

\ 3. Loosen the adjusting bolt (Fig. 6–20).

4. Move the alternator to get the correct adjustment on the belt of 1/4” (6,35 mm) movement with 5 lbs. of pressure between the sheaves.

5. Tighten the adjusting bolt (Fig. 6–20).

6. Tighten the top mounting bolt (Fig. 6–19).

7. Close the rear door.

B–05170 B–05167

Fig. 6–20 Adjusting Bolt 6–7.2 Checking the Alternator

Dealer Copy -- Not for Resale

No. 1 Terminal

No. 2 Terminal

”Bat” Terminal Lift the loader and put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

Test Hole To check the wiring harness use the following procedure:

B–02113

Fig. 6–21 Terminal Location for the Alternator

1. Turn the key switch to the “ON” position.

2. Connect a voltmeter between the ground and the No. 1 connector plug (Fig. 6–21) and check the voltage.

terminal of the

3. Connect a voltmeter between the ground and the No. 2 connector plug (Fig. 6–21) and check the voltage.

terminal of the

4. Connect the voltmeter between ground and the “Bat” terminal with the wire connected (Fig. 6–21) and check the voltage.

5. If any of the tests in Steps 2, 3 & 4 show zero voltage, the wiring has a defect.

6. Find the defect in the wiring, make repair and check the voltage again.

To check the alternator output, use the following procedure: 1. Stop the engine. Open the rear door.

2. Disconnect the negative cable from the battery.

145 of 256

–6–7–

540, 543 Loader Service Manual

3. Disconnect the “Bat” connector at the alternator and connect it to one connector of an ammeter. Connect the other side of the ammeter to the “Bat” terminal of the alternator.

Test Hole

4. Connect the negative cable at the battery.

5. Make sure the throttle lever is fully back.

6. Turn the engine, with the starter, for 30 seconds to lower the charge in the battery.

A–02211 B–02113

Fig. 6–22 Checking Regulator

B–05170

Fig. 6–23 Removing Adjusting Bolt

7. Push the throttle lever forward and start the engine and run at full RPM.

9. If the reading is correct, the alternator is good. If the reading is more or less than 10% of rated amperage, check the regulator.

B–05180

Fig. 6–26 Removing the Belt

B–05165

Fig. 6–25 Removing Top Bolt

To check the regulator, use the following procedure: 1. Use Steps 2 thru 7 for alternator output.

2. Put a small screwdriver in the test hole (Fig. 6–22).

3. If the ammeter is within 10% of rated amperage (which is 37 amps at 2750 RPM) the regulator is good. If the reading is not within 10% of rated amperage, check the diode trio, rectifier , stator or rotor (See Paragraph 6–7.4).

6–7.3 Removing the Alternator 1. Stop the engine. Open the rear door.

2. Disconnect the negative cable from the battery.

3. Remove the engine blower housing from the engine (See Paragraph 7B–3.1, Page 7B–9).

4. Remove the adjustment bolt (Fig. 6–23).

5. Remove the belt (Fig. 6–24).

6. Remove the top bolt from the mounting bracket (Fig. 6–25).

7. Remove the alternator from the mounting bracket.

8. Disconnect the connector from the alternator (Fig. 6–26, Item 1).

9. Remove the wire from the alternator (Fig. 6–26, Item 2).

146 of 256

–6–8–

B–05182

Fig. 6–26 Disconnect Alternator Wires 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

8. The ammeter reading must be within 10% of the rated amperage (which is 37 amps at 2750 RPM).

6–7.4 Repairing the Alternator 1. Put a mark across the alternator case for correct assembly.

Check for Ground

2. Remove the sheave from the alternator shaft.

3. Remove the four (4) bolts that hold the case halves together.

4. Use a screwdriver to pry the case halves apart.

5. Remove the rotor from the housing.

6. Remove the three (3) nuts that hold the stator wires to the housing. Remove the stator.

7. Disconnect the diode trio.

9. Connect the ohmmeter between both slip rings. There must be 2.3 to 3 ohms of resistance. If there is not, there is a defect in the rotor (Fig. 6–27).

10. Connect a test light between the center wire and one of the outside wires on the stator (Fig. 6–28). If the light does not come “ON” there is a defect.

Check for Shorts and Opens

A–01857

Fig. 6–27 Checking Rotor

Check for Opens

Check for Grounds

Check for Opens

B–02108

Dealer Copy -- Not for Resale

8. Connect the ohmmeter between one slip ring and the shaft. There must be maximum resistance (Fig. 6–27).

11. Connect the test light between the center wire and the other side outside wire (Fig. 6–28). If the light does not come “ON” there is a defect.

12. Connect the test light between one of the wires and the stator frame (Fig. 6–28). If the light comes “ON” there is a defect.

IMPORTANT

Do not use high voltage to check diode trio or rectifier.

Fig. 6–28 Checking Stator 13. Connect a D.C. test light between the single connection and on one of the three (3) connections (Fig. 6–29). Connect the tester in the opposite direction. The light must come “ON” in one direction, but not in the other direction.

14. Do Step 13 for the otherdiodes.

Insulated Heat Sink

15. Connect the test light between the center connections and each outside connection. If the light comes “ON” on either side, there is a defect.

16. Remove the rectifier from the alternator.

17. Connect a test light between one connection and the insulated heat sink (Fig. 6–30).

Connect the test light in the other direction. The light must come “ON” in one direction but not in the other direction.

147 of 256

Grounded Heat Sink

B–02101 B–02102

A–02382

Fig. 6–29 Checking Diode Trio –6–9–

Fig. 6–30 Checking Rectifier 540, 543 Loader Service Manual

18. Connect the test light between the same connection and ground heat sink (Fig. 6–30).

Connect the tester in the other direction. The light must come “ON” in one direction, but not in the other direction.

Insulated Washers

19. Do Steps 17 & 18 on both the other connections. If any of the tests are bad, make replacement of the rectifier.

B–02128

20. Install the rectifier.

Fig. 6–31 Insulated Washers

B–02097

Fig. 6–32 Holding Brushes

21. If the regulator is removed, make sure when installing it to replace the two (2) insulated washers and spacers (Fig. 6–31).

23. Install the stator and connect the wires.

24. Install the new brushes and put a piece of straight wire through the housing to hold the brushes in the up position.

B–05165

Fig. 6–34 Installing Top Bolt

25. Install the rotor and remove the wire.

26. Put the case halves together and install the bolts and tighten.

27. Install the sheave and tighten the nut to 50 ft.–lbs. (68 Nm) torque.

B–05182

Fig. 6–33 Connecting Alternator Wires

B–05180

6–7.5 Installing the Alternator

Fig. 6–35 Installing the Belt

1. Connect the wire at the alternator (Fig. 6–33, Item 1).

2. Connect the wire connector to the alternator (Fig. 6–33, Item 2).

3. Put the alternator in the mounting bracket and installthe top bolt (Fig. 6–34).

4. Install the belt (Fig. 6–35).

5. Install the adjusting bolt. Do not tighten (Fig. 6–36).

148 of 256

B–05170

Fig. 6–36 Installing Adjustment Bolt –6–10–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

22. Install the diode trio.

6. Adjust the alternator belt for the correct tension.

7. Install the engine blower housing (See Paragraph 7B–3.4, Page 7B–13).

8. Connect the negative cable to the battery.

6–8 STARTER (540)

1

6–8.1 Checking the Starter 1. Make sure the ignition is in the “OFF” position. Make sure the battery has a full charge and the cable connections are clean and tight.

2. Connect the jumper wire between the solenoid connection (Fig. 6–37, Item 1) and the “BAT” connection (Fig. 6–37, Item 2). If the starter turns but the engine does not, the defect is in the starter drive. If the starter does not turn, go to Step 3.

2 3

B–05183

Fig. 6–37 Starter Solenoid (540)

Dealer Copy -- Not for Resale

3. Connect a jumper wire between the “M” connection (Fig. 6–37, Item 3) and the “BAT” connection (Fig. 6–37, Item 2). If the starter turns the defect is in the solenoid.

6–8.2 Removing the Starter 1. Stop the engine. Open the rear door.

2. Disconnect the negative cable from the battery.

Starter Bolts

3. Remove the wire from the starter (Fig. 6–38).

4. Remove the starter bolts (Fig. 6–39).

5. Remove the starter from the engine.

B–05187

Fig. 6–38 Starter Wires

B–05189

Fig. 6–39 Starter Bolts

6–8.3 Repairing the Starter 1. Pull the rubber cap off the end of the starter shaft.

2. Use two (2) wrenches to remove the nut on theend of the starter shaft (Fig. 6–40).

3. Remove the starter drive parts (Fig. 6–41).

4. Put a mark on the side of the starter housing and end plates for easier assembly.

149 of 256

B–02839

Fig. 6–40 Starter Drive Nut –6–11–

B–02862

Fig. 6–41 Starter Drive Parts 540, 543 Loader Service Manual

5. Check the condition of the brushes. If the brushes areless than 5/16” (8 mm) in length, install new brushes (Fig. 6–42).

6. Check the commutator (Fig. 6–43) and check the armature in the growler.

B–02878

Fig. 6–42 Checking Brushes

NOTE: DO NOT put lubricant on the starter drive splines.

Fig. 6–43 Checking Commutator

Jumper Wire Bat S M

6–9 STARTER (543) 6–9.1 Checking the Starter

Jumper Wire

Solenoid Bat S M Cranking Motor

Cranking Motor

1. Make sure the ignition is in the “OFF” position. Make sure the battery has a full charge and the cables are clean and tight.

B–02860

A–01992

2. Connect a jumper wire between the “S” connection and “BA T” connection (Fig. 6–44). If the starter turns, but the engine does not turn, the defect is in the starter drive. If starter does not turn go to Step 3.

Fig. 6–44 Checking Starter

A–01991

Fig. 6–45 Checking Starter

3. Connect a jumper wire between the “M” connection and the “BAT” connection (Fig. 6–45). If the starter turns, there is a defect in the solenoid.

B–05185

Fig. 6–46 Solenoid Wires 6–9.2 Removing the Starter 1. Stop the engine. Open the rear door.

2. Disconnect the negative cable from the battery.

3. Remove all the wires from the starter solenoid (Fig. 6–46).

4. Remove the starter mounting bolts (Fig. 6–47).

B–05190

5. Remove the starter from the engine.

150 of 256

Fig. 6–47 Starter Bolts –6–12–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

7. Check all the parts of the starter for damage. Add lubricant to the bushings and assemble the starter parts.

6–9.3 Repairing the Starter 1. Disconnect the connector link between the solenoid and starter.

7 2. Remove the solenoid bolts (Fig. 6–48, Item 1) that fasten the solenoid to the drive end of the starter.

2

3

1

4

4. Remove the bolt (Fig. 6–48, Item 3) and remove the shift fork (Item 4).

5. Remove the bolts (Fig. 6–48, Item 5) from the end cap (Item 6).

12 13

9

5

14 10 6

11 15

Dealer Copy -- Not for Resale

3. Remove the solenoid (Fig. 6–48, Item 2).

8

C–02199

Fig. 6–48 Starter Assembly

6. Remove the shim washers (Fig. 6–48, Item 7) from the armature (Item 8) shaft at the commutator end.

7. Remove the armature, complete with the internal thrust washer (Fig. 6–48, Item 9) and the drive assembly (Item 10) through the drive end of the starter frame.

8. Remove the thrust washer (Fig. 6–48, Item 11) from the commutator end of the armature shaft.

9. Remove the drive shaft ring (Fig. 6–48, Item 12), thrust collar (Item 13) and slide the drive assembly off the armature shaft.

10. Use a brush and air pressure to clean the drive, field coils, armature, front plate and rear housing.

NOTE: DO NOT use solvent to clean the drive assembly because the solvent will remove the lubricant and the drive will slip.

151 of 256

–6–13–

540, 543 Loader Service Manual

11. Inspect the armature for broken or burned insulation and loose connections at the commutator.

12. Check the armature for opens and grounded circuits (Fig. 6–49 & 6–50).

13. Check the armature shaft and bearings for damage and wear commutator is rough, cut it in a lathe to make is smooth.

. If the

14. Check the brush holders for broken springs and for broken insulation.

A–01995

Fig. 6–49 Checking Armature

15. Check the spring tension for the brushes.

17. Check the starter drive gear for tooth wear . The starter drive gear must engage more than 1/2 the depth of the ring gear teeth on the flywheel.

18. Put a small amount of grease on the shaft of the armature (Fig. 6–48, Item 8). Install the drive assembly (Item 10) and install the thrust collar (Item 13) and the stop ring (Item 12).

A–01994

Fig. 6–50 Checking Armature

19. Install the thrust washer (Fig. 6–48, Item 11) on the shaft of the armature.

20. Install the armature into the starter housing.

21. Install the brushes in the end plate (Fig. 6–48, Item 14) and install the end plate on the starter housing.

22. Put a small amount of grease in the gushing (Fig. 6–48, Item 15) and install the drive housing end.

23. Install the bolts (Fig. 6–48, Item 5) and tighten. Check the end play of the starter. If there is too much end play or not enough, add or remove shims (Item 17) at the drive end of the armature.

24. Install the shift fork (Fig. 6–48, Item 4) and the pivot bolts (Item 3) and tighten.

25. Install the solenoid (Fig. 6–48, Item 2). Install the bolts (Item 1) and tighten.

26. Connect the link between the solenoid and the starter.

152 of 256

–6–14–

B–02122

Fig. 6–51 Checking Field Coils 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

16. Inspect the field coils for burns or broken insulation and electrical continuity (Fig. 6–51). Check the field brush connections and wire insulation.

6–9.4 Installing the Starter 1. Install the starter into the flywheel housing.

2. Install the starter mounting bolts (Fig. 6–52) and tighten to 25–28 ft.–lbs.

(34–38 Nm) torque.

B–05190

3. Connect the wires to the solenoid (Fig. 6–53).

Dealer Copy -- Not for Resale

Fig. 6–52 Starter Bolts

4. Connect the negative cable at the battery.

5. Close the rear door.

B–05185

Fig. 6–53 Solenoid Wires

153 of 256

–6–15–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 154 of 256

–6–16–

540, 543 Loader Service Manual

ENGINE SERVICE (KOHLER–540) . . . . . . . . . . . . . . .

ENGINE SERVICE (ISUZU–543) . . . . . . . . . . . . . . . . .

Paragraph Number

Page Number

7A–1 7B–1

7A–1 7B–1

ENGINE SERVICE

Dealer Copy -- Not for Resale

ENGINE SERVICE

540 KOHLER

543 ISUZU

WARNING

155 of 256

DO NOT service the Bobcat loader without instructions or taking the necessary safety precautions.

Before working on the loader , see the warnings and instructions at the beginning of this Service Manual.

After making the repair or adjustment, always check the function of the loader . Failure to obey warnings may cause injury or death.

–7A––3–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 156 of 256

–7A––2–

540, 543 Loader Service Manual

ENGINE SERVICE (540) Page Number

7A–3 7A–2 7A–10 7A–5 7A–12 7A–4 7A–11 7A–8 7A–9 7A–6

7A–6 7A–3 7A–15 7A–8 7A–15 7A–7 7A–15 7A–12 7A–13 7A–10

7A–7 7A–1

7A–11 7A–1

Dealer Copy -- Not for Resale

CARBURETOR & FUEL SHUT–OFF SOLENOID . . . . . . . . . . . . . .

CHECKS & ADJUSTMENTS . . . . . . . . . . .

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . .

ENGINE & HEAT SHIELD . . . . . . . . . . . . .

FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . .

GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . .

INTAKE & EXHAUST MANIFOLD . . . . . .

OIL PUMP & RELIEF VALVE . . . . . . . . . .

PISTONS, RODS AND CRANKSHAFT . .

RECONDITIONING THE VALVES . . . . . .

TIMING COVER, TIMING GEARS & CAMSHAFT . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING . . . . . . . . . . . . . . . .

Paragraph Number

540 KOHLER

WARNING

157 of 256

DO NOT service the Bobcat loader without instructions or taking the necessary safety precautions.

Before working on the loader , see the warnings and instructions at the beginning of this Service Manual.

After making the repair or adjustment, always check the function of the loader . Failure to obey warnings may cause injury or death.

–7A––1–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 158 of 256

–7A–0–

540, 543 Loader Service Manual

7A ENGINE SERVICE–540 LOADER (KOHLER) 7A–1 TROUBLESHOOTING The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

CAUSE

Slow cranking speed.

1, 2, 3, 4

Engine will not start.

5, 6, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 19, 27, 28, 29, 30

Difficult to start.

5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 21, 26, 27, 28, 29, 30

No power from the engine.

7, 8, 9, 10, 11, 14, 16, 17, 18, 19, 20, 21, 22, 23, 24, 27, 28, 29, 30

Engine is mis–firing.

7, 8, 9, 10, 14, 16, 17, 22, 25, 26, 27, 28, 29, 30

Too much fuel consumption.

7, 11, 14, 17, 20, 21, 22, 24, 25, 26, 27, 28, 29, 30

Black exhaust.

7, 11, 14, 16, 17, 19, 21, 22, 24, 25, 26, 28, 29, 30

Low oil pressure.

4, 32, 33, 34, 35, 36, 38, 39, 40, 46

Engine knocking.

9, 16, 23, 25, 26, 28, 30, 32, 41, 47

Engine running rough.

7, 8, 9, 10, 11, 14, 15, 17, 18, 20, 23, 25, 26, 27, 30, 41, 47

Vibration.

14, 15, 17, 20, 22, 23, 26, 27, 30, 41, 43

High oil pressure.

4, 34, 37

Overheating.

11, 16, 21, 41, 42

Too much crankcase pressure.

22, 28, 30, 31, 41, 44

Poor compression.

16, 22, 25, 26, 28, 29, 30, 31

Start and stop.

10, 11, 12

159 of 256

–7A–1–

Dealer Copy -- Not for Resale

PROBLEM

540, 543 Loader Service Manual

7A–1 TROUBLESHOOTING (Cont’d)

1. Battery capacity low.

25. Incorrect valve tappet adjustment.

2. Bad electrical connection.

26. Sticking valves.

3. Faulty starter motor.

27. Spark plug gap not correct.

4. Incorrect grade of oil.

28. Worn cylinder bores.

5. Low cranking speed.

29. Worn valves and seats.

6. Fuel tank empty.

30. Broken, worn or sticking piston rings.

7. Ignition system has damage.

31. Worn valve stems or guides.

8. Plugged fuel line.

32. Worn or damaged bearings.

9. Faulty fuel lift pump.

33. Not enough oil in the oil pan.

10. Plugged fuel filter.

34. Gauge is not correct.

11. Restriction in the air cleaner.

35. Oil pump is worn.

12. Wrong starting procedure.

36. Pressure relief valve is open.

13. Choke not completely closed.

37. Pressure relief is sticking closed.

14. Choke not completely opened.

38. Broken relief valve spring.

15. Carburetor is dirty or has a defect.

39. Faulty suction pipe.

16. Incorrect valve timing.

40. Plugged oil filter.

17. Poor compression.

41. Piston seizure.

18. Plugged fuel tank vent.

42. Damaged fan.

19. Dirt or water in the fuel.

43. Faulty engine mounting.

20. Sticking or restricted throttle.

44. Plugged breather pipe.

21. Exhaust pipe restriction.

45. Valve stem seals damaged.

22. Cylinder head gasket leaking.

46. Plugged oil pump pipe strainer.

23. Overheating.

47. Broken valve spring.

24. Governor adjustment not correct.

160 of 256

–7A–2–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

KEY TO CORRECT THE CAUSE

7A–2 CHECKS & ADJUSTMENTS Pressure Gauge

7A–2.1 Oil Pressure When the engine is operating at normal temperature, with the correct weight oil and at idle speed, the oil pressure must be within 40–50 PSI (276–345 kPa). If the oil pressure is higher than specified, it will notcause damage, but it could indicate that it is operating with the oil weight too thick. If the oil pressure drops suddenly, this could indicate that the oil pump is faulty or the check valve is not working correctly and has debris in it.

If the oil pump is faulty, do not attempt to disassemble and repair the pump.

Replace the oil pump with a new pump. There is an external oil pressure adjustment available.

Check the engine oil pressure using the following procedure:

Fig. 7A–1 Checking Oil Pressure

Lift the loader and put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

Dealer Copy -- Not for Resale

WARNING

B–02909

1. Stop the engine. Open the rear door.

2. Remove the oil pressure sender from the gauge (Fig. 7A–1).

3. Start the engine and run it until it is at operation temperature.

engine and install a pressure

Acorn Nut* Lock Nut

Self Locking Nut

4. Check the oil pressure at full engine RPM. The pressure must be 40–50 PSI (276–345 kPa).

5. Make the adjustment of the oil pressure by loosening the jam nut under the No. 1 cylinder (next to the flywheel) and turn the adjustment bolt in or out to get the correct oil pressure (Fig. 7A–2).

7A–2.2 Valve Clearance

Adjusting Bolt *Early Models Have Acorn Nut

PI–01908

Fig. 7A–2 Oil Pressure Adjustment

Valve–Tappet Clearance

Make the valve adjustment with the engine stopped and cold.

Put the correct size feeler gauge between the tappet and the valve stem and turn the adjustment bolt in or out to get the correct clearance.

The correct clearance for the intake is 0.008–0.010” (0,203–0,254 mm) and the exhaust is 0.017–0.020” (0,432–0,508 mm) (cold) (Fig. 7A–3).

PI–01911

Fig. 7A–3 Valve Clearance Adjustment 161 of 256

–7A–3–

540, 543 Loader Service Manual

Use the following procedure to set the valve clearance:

1

4

1. Remove the covers from the valve chambers.

2

2. Turn the crankshaft until there is maximum clearance between the valve stem and tappet.

3. Check the clearance with a feeler gauge (Fig. 7A–3).

3

4. If the clearance is wrong, turn the bolt at the end of the tappet until the clearance is correct.

Speed Control Bracket

B–02282

Fig. 7A–4 Governor Linkage 7A–2.3 Compression 1. Make sure the engine is at operating temperature.

1

2. Remove both spark plugs.

4. Disconnect the high voltage wire from the coil.

5. Install the compression gauge in the cylinder to be checked.

6. Turn the engine several times with the starter . Check the gauge. The compression must be 100–120 PSI (689–827 kPa).

C–02338

Fig. 7A–5 Throttle Lever Stops

7A–2.4 Throttle and Governor Linkage

WARNING

2

Lift the loader and put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

1 3

1. Stop the engine. Disconnect the throttle linkage (Fig. 7A–4, Item 1) between the carburetor and the governor arm (Fig. 7A–4, Item 2).

PI–01905

Fig. 7A–6 Carburetor Adjustment

2. Hold the throttle on the carburetor fully open. Put the governor arm against its stop. Adjust the length of the throttle linkage (Fig. 7A–4, Item 1) so it will fit.

3. Push the throttle control fully forward. The speed stop bolt (Fig. 7A–4, Item 3) must be against the stop. If not, make the adjustment at the stop bolts at the throttle lever (Fig. 7A–5, Item 1).

4. Start the engine and run it at idleRPM. Turn the idle adjustment (Fig. 7A–6, Item 1) to get the fastest idle RPM. Then make an adjustment to the idle fuel adjustment (Fig. 7A–6, Item 2) for correct low RPM. 5. Run the engine at full throttle. Put a load on the engine(engage the auxiliary or tilt the Bob–Tach all the way back). Turn the main fuel adjustment (Fig. 7A–6, Item 3) in or out to get a smooth engine operation.

162 of 256

–7A–4–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

3. Open the throttle and choke fully.

6. Disengage the load. Check the high–idle RPM. T urn the speed RPM stop bolt to get the correct RPM. 7. Engage and release the load at full engine RPM. If the governor action for the engine RPM changes is not smooth, connect the governor spring (Fig. 7A–4, Item 4) to a lower hole on the governor arm. If the engine RPM becomes slower, move the spring to a higher hole in the governor arm.

8. If the location of the spring was changed, check the high–idle RPM again.

B–03385

Fig. 7A–7 Adjusting the Points

7A–2.6 Ignition System

1. Stop the engine. Open the rear door.

2. Remove the cover from the points at the governor.

Dealer Copy -- Not for Resale

WARNING

Lift the loader and put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

B–02910

Fig. 7A–8 Timing the Engine

3. Remove the old points.

4. Install the new points. Turn the engine until maximum point gap is reached.

5. Adjust the point gap to 0.020” (0,51 mm) (Fig. 7A–7).

6. Remove the cover for the timing hole (Fig. 7A–8, Item 1). Turn the flywheel until the “SP” mark is in the timing hole. Put a chalk mark on the “SP” mark.

7. Start the engine and run it at 1200 RPM. 8. If the timing mark is not correct, loosen the two (2) governor bolts and move the governor until the “SP” mark shows in the timing hole.

9. Stop the engine.

10. Check the adjustment of the idle RPM. 11. Remove the jackstands from under the loader frame.

7A–2.7 Spark Plugs Every 100 hours of loader operation, remove the spark plugs,check the condition and set the gap. Good operating conditions are indicated if the spark plugs have a light coat of gray or tan deposit. A dead white, blistered coating could indicate overheating. A black (carbon) coating may indicate an “over–rich” fuel mixture caused by clogged air cleaner or the carburetor adjustment is not correct. Replace the spark plugs as needed.

163 of 256

–7A–5–

540, 543 Loader Service Manual

7A–3 CARBURETOR & FUEL SHUT–OFF SOLENOID

Idle Fuel Needle

7A–3.1 Removing the Carburetor

Main Fuel Needle

1. Stop the engine. Open the rear door.

2. Disconnect the air hose.

cleaner

Carburetor Body

3. Disconnect the fuel line.

4. Disconnect the linkage fromthe carburetor.

5. Remove the bolts and nuts which hold the carburetor to the manifold.

Bowl Gasket

NOTE: To install the carburetor , use the above procedure in reverse. Make sure to check adjustment of the linkage for the governor (See Paragraph 7A–2.4).

Always use new gaskets.

Fuel Inlet Needle & Seat

Baffle

Pin

Fuel Bowl

7A–3.2 Disassembly and Inspection of the Carburetor (Fig. 7A–9) 1. Remove both mixture screws and springs.

PI–01912

Fig. 7A–9 Carburetor Assembly

2. Remove the plug from the float bowl. Remove the bowl from the carburetor body.

3. Remove the float pin, float and needle.

4. Remove the seat from the carburetor body.

5. Clean all parts. Do not remove the throttle and choke plates unless they are damaged.

6. Check the float for bends or damage.

7. Check the end of the mixture needles for damage.

7A–3.3 Assembly of the Carburetor (Fig. 7A–9).

NOTE: Use new gaskets and float valve and seat when assembling the carburetor.

1. Install the new float valve seat in the carburetor.

2. Put a new bowl gasket and baffle in position.

3. Install the needle on the float. Install the float on the carburetor body.

4. Turn the carburetor so the bottom is up. The float must be parallel to the gasket surface of the carburetor body . If not, bend the tab on the float to adjust the float level.

5. Install the bowl. Install the fuel bowl plug and tighten.

6. Install the mixture needles in the carburetor.

164 of 256

–7A–6–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

Float

7A–3.4 Fuel Shut–off Solenoid The loader is equipped with a fuel shut–of f solenoid (Fig. 7A–10). The shut–of f solenoid shuts the fuel off when the ignition switch is turned to the “OFF” position to prevent the engine from running on (dieseling).

NOTE: There is also an electrically operated shut–off located in the carburetor fuel inlet.

B–05193

Fig. 7A–10 Fuel Shut–off Solenoid

7A–4 GOVERNOR 7A–4.1 Removing the Governor 1. Stop the engine. Open the rear door.

2. Disconnect the linkage from the governor.

4. Remove the engine shrouding from the right cylinder to reach the lower governor bolt.

5. Remove the governor bolts.

6. Remove the crankcase breather.

Dealer Copy -- Not for Resale

3. Disconnect the hose from the governor.

B–02883

Fig. 7A–11 Removing the Points

7. Remove the governor from the engine.

NOTE: The governor must be replaced as an assembly and can not be repaired.

Remove the ignition point cover, ignition points (Fig. 7A–11), push rod and linkage from the governor.

Install these parts on the new governor.

Bevel on Gear

7A–4.2 Installing the Governor 1. Remove the plug from the top of the governor adapter and ignition timing hole (Fig. 7A–12).

2. Turn the flywheel so the “D.C.” mark can be seen.

3. Install the governor so the bevel on the gear is in alignment with the hole in the governor adapter (Fig. 7A–12).

4. Check the adjustment of the timing and governor linkage.

165 of 256

B–02293

Fig. 7A–12 Installing the Governor –7A–7–

540, 543 Loader Service Manual

7A–5 ENGINE AND HEAT SHIELD 7A–5.1 Removing the Engine

Lift the loader and put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

B–05194

Fig. 7A–13 Muffler Clamp Bolt

B–05195

Fig. 7A–14 Removing the Muffler

1

Dealer Copy -- Not for Resale

1. Remove the rear door (See Paragraph 5–4.1 or 5–4.2, Page 5–9).

2. Remove the battery (See Paragraph 6–3.1, Page 6–3).

3. Remove the muf fler clamps (both sides) (Fig. 7A–13).

4. Remove the muffler from the engine (Fig. 7A–14).

B–05357

Fig. 7A–15 Fuel Line & Cable

5. Disconnect the fuel line from the carburetor (Fig. 7A–15, Item 1).

6. Move the clamp on the choke cable away from the heat shield.

7. Disconnect the choke cable at the carburetor (Fig. 7A–16).

8. Disconnect the throttle linkage at the pivot shaft on the heat shield.

A–02779

Fig. 7A–16 Disconnect the Choke

B–05198

Fig. 7A–17 Air Cleaner Hose

9. Remove the air cleaner hose from the carburetor (Fig. 7A–17).

10. Remove the nuts and bolts at the starter solenoid (Fig. 7A–18). Remove the starter solenoid with the engine.

11. Remove the bolts which hold the engine to the hydrostatic pumps.

12. Remove the engine mounting bolts (both sides) (Fig. 7A–19).

B–05199

Fig. 7A–18 Starter Solenoid 166 of 256

–7A–8–

B–05200

Fig. 7A–19 Engine Mount Bolt 540, 543 Loader Service Manual

13. Remove the bolts and nuts (both sides) from the heat shield whichhold it to the engine mounting brackets.

14. Install the engine removal table (Fig. 7A–20, Item 1) at the rear of the loader .

15. Slide the engine out of the rear of the loader on the table (Fig. 7A–20).

7A–5.2 Installation of the Engine 1. Slide the engine into the loader until the crankshaft is in contact with the drive coupler. Make alignment of the drive coupler to the splines on the engine.

1 B–05201

2. Install the engine mounting bolts and tighten (both sides) (Fig. 7A–19).

Fig. 7A–20 Engine Removal

Dealer Copy -- Not for Resale

3. Install the bolts in the heat shield and the engine mounting brackets. Install the nuts and tighten.

4. Install the bolts which hold the engine to the hydrostatic pump and tighten to 65–70 ft.–lbs. (88–95 Nm) torque.

5. Install the bolts and nuts in the starter solenoid and tighten (Fig. 7A–18).

6. Install the air cleaner hose (Fig. 7A–17).

7. Connect the choke cable and the throttle linkage at the carburetor (Fig. 7A–16).

8. Connect the fuel line (Fig. 7A–15).

9. Install the muffler (Fig. 7A–14) and tighten the clamps (Fig. 7A–13).

10. Install the battery in the loader (See Paragraph 6–3.3, Page 6–4).

B–05203

Fig. 7A–21 Drive Coupler 11. Install the rear door (See Paragraph 5–4.1 or 5–4.3, Page 5–10).

7A–5.3 Removing the Heat Shield 1. Remove the engine from the loader (See Paragraph 7A–5.1).

2. Remove the drive coupler from the hydrostatic pump (Fig. 7A–21).

3. Remove the clamp from the choke cable (Fig. 7A–22).

167 of 256

–7A–9–

B–05205

Fig. 7A–22 Choke Cable Clamp 540, 543 Loader Service Manual

4. Remove the four (4) bolts and nuts for the mounting bracket for the throttle jackshaft (Fig. 7A–23).

5. Remove the throttle jackshaft and the throttle mounting bracket (Fig. 7A–24).

6. Using a long pry bar, lift the hydrostatic pump up (Fig. 7A–25) and slide the heat shield out and away from the hydrostatic pump.

7A–5.4 Installing the Heat Shield 1. Lift the hydrostatic pumps with a long pry bar. Slide the heat shield up and on the hydrostatic pump (Fig. 7A–25).

B–05207

Fig. 7A–23 Throttle Bracket

2. Install the throttle mounting bracket and tighten the bolts and nuts (Fig. 7A–23). mounting

4. Put the choke cable through the hole in the heat shield and install the choke cable clamp (Fig. 7A–22).

5. Install the drive coupler on the splines of the hydrostatic pump (Fig. 7A–21).

B–05209

6. Install the engine in the loader (See Paragraph 7A–5.2).

Fig. 7A–24 Throttle Jackshaft

7A–6 RECONDITIONING THE VALVES 7A–6.1 Repair of the Valves and Guides 1. Remove the engine from the loader (See Paragraph 7A–5.1).

2. Remove the shrouding, cylinder heads and the valve chamber covers.

3. Turn the crankshaft and check the amount of valve lift. If not enough, the cam is worn and needs to be replaced (See Section 8 for the Specifications).

B–05211

4. Use a valve spring compressor to remove the valve springs (Fig. 7A–26).

Fig. 7A–25 Engine Heat Shield

NOTE: There are valve rotators under the exhaust valve springs.

The exhaust valve springs are shorter.

The close coils of the springs go toward the cylinder heads.

5. Check the clearance between the valves and guides. If over maximum, remove the guides and install new guides.

6. Use a reamer, of the correct size, in the new guides to make them fit the valve stems.

168 of 256

PI–01910

Fig. 7A–26 Removing Valve Springs and Locks –7A–10–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

3. Install the throttle jackshaft into the heat shield and the throttle bracket.

7. Check the exhaust valve seat for wear, distortion or cracks. Use a valve seat tool to remove the old seats, if needed.

NOTE: The exhaust valve seat is the only seat that can be replaced.

Gear Cover Alignment

8. Grind the valves and seats. Use a grinding compound to check that the valves are fitted correctly and the seat is at the correct width.

Carefully inspect the valve mechanism parts. Check valves and valve seat areas or inserts for a condition of deep pitting, cracks or distortion. Check the clearance of the valve stems in the guides.

7A–7 TIMING COVER, TIMING GEARS AND CAMSHAFT 7A–7.1 Timing Cover 1. Remove the air housing for the flywheel.

2. Remove the bolts which hold the timing cover in position and slide it off the crankshaft.

3. When installing the timing cover, make note of the two special bolts (Fig. 7A–27). Install and tighten these two bolts first.

Second Hole Up Third Hole Up PI–01906

Fig. 7A–27 Timing Cover

Dealer Copy -- Not for Resale

If the valve seat insert is badly worn, warped, damaged or if seating surface is badly pitted, the insert must be replaced. The inserts are a tight press fit in the cylinder head. A valve seat removal tool is used for this job. Since the insert removal causes loss of metal in the insert borearea in the head, use only service replacement inserts which have a knurled edge to provide proper fit in the cylinder head. Make sure the service inserts are properly startedand pressed into the bore to prevent the insert from seating at an angle.

7A–7.2 Timing Gears While the timing cover is of f the engine, the gears can be removed.

The camshaft gear is removed by putting a block of wood between the gear teeth and removing the nut from the camshaft. Then remove the gear from the camshaft. Remove the snap ring from the end of the crankshaft and remove the crankshaft gear.

NOTE: If the oil pump gear needs replacement, you must replace the oil pump assembly.

Make sure the timing marks are in correct alignment when installing the gears (Fig. 7A–28).

169 of 256

PI–01909

Fig. 7A–28 Timing Marks Alignment –7A–11–

540, 543 Loader Service Manual

7A–7.3 Camshaft and Tappets The gear cover must be removed to remove the camshaft gear . Remove all of the bolts which hold the gear cover plate in place. Remove the cylinder heads and valves. Turn the camshaft to push the tappets out of the way and remove the camshaft from the engine.

NOTE: If the camshaft is replaced, the tappets must also be replaced. To replace the tappets, you must remove the oil pan.

1

B–02861

Fig. 7A–29 Relief Valve

7A–8 OIL PUMP AND RELIEF VALVE 7A–8.1 Relief Valve

B–02856

Fig. 7A–30 Oil Pump

7A–8.2 Oil Pump If the oil pump has a defect, you must replace the oil pump as an assembly.

To remove the oil pump, remove the oil panand remove the oil pump screen. Then remove the flywheel and gear cover. Replace the two (2) bolts which hold the oil pump to the engine block and lift it out of the engine (Fig. 7A–30).

7A–8.3 Adjusting Gear Clearance for the Oil Pump When installing the oil pump on the engine, it is important to adjust the clearance between the oil pump gear and the crankshaft gear. The clearance between the gears is 0.005–0.009” (0,127–0,228 mm). A feeler gauge or a dial indicator can be used.

To set the clearance with a feeler gauge: 1. After the oil pump is installed, do not tighten the bolts.

2. Use a 0.007” (0,177 mm) feeler gauge and adjust the clearance between the oil pump and crankshaft gear (Fig. 7A–31).

Tighten the mounting bolts.

A–02643

Fig. 7A–31 Checking Gear Clearance 170 of 256

–7A–12–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

The relief valve for the oil pressure is under the No. 1 cylinder (Fig. 7A–29, Item 1). The oil pressure is adjusted by loosening the jam nut and turning the screw in or out (See Paragraph 7A–2.1).

3. Check the clearance at two other locations (120° from each other) to make sure the clearance is correct.

4. If one or more locations do not have the same clearance, loosen the bolts and adjust the clearance until all three locations have the same clearance.

To set the clearance with a dial indicator: 1. After the oil pump is installed, do not tighten the mounting bolts.

A–02642

Dealer Copy -- Not for Resale

Fig. 7A–32 Checking Gear Clearance 2. Mount a dial indicator on the engine (Fig. 7A–32). Makesure the dial indicator arm is tight against one of the gear teeth. Zero the dial indicator.

3. Adjust the clearance by moving the oil pump backward and forward until the clearance is between 0.005–0.009” (0,127–0,228 mm). T ighten the mounting bolts.

4. Check the clearance at two other locations (120° from each other) to make sure the clearance is correct.

5. If one or more locations do not have the same clearance, loosen the bolts and adjust the clearance until all three locations have the same clearance.

C–02339

7A–9 PISTONS, RODS AND CRANKSHAFT

Fig. 7A–33 Removing Piston

7A–9.1 Removing Pistons, Rods and Crankshaft 1. Remove the engine flywheel, oil pan and oil pump.

2. Put a mark on the rods and caps. The caps, rods and pistons must be installed in the cylinder bore they were removed from.

NOTE: The notch on the cap and the notch on the rod must be together .

3. Remove the rod bolts and caps and remove the pistons from the engine (Fig. 7A–33).

4. Remove the adapter and the bearing plate and the snap ring from the end of the crankshaft. Remove the bearing plate, with the bearing, from the engine.

5. Remove the crankshaft from the engine. Be careful to prevent damage to the bearing in the engine block.

171 of 256

–7A–13–

540, 543 Loader Service Manual

6. Check the following items: (a) Crankshaft: Keyway, journal diameters, out–of–round conditions. (b) Rods: Condition of the bearing surface. (c) Pistons: Scratch marks, ring groove, clearance, cracks or damage. (d) Cylinder Block: Condition of the bearings, cylinder walls.

A–02780

Fig. 7A–34 Installing Bearing

7A–9.2 Crankshaft Bearing and End Play

To replace the bearing, remove the inner retaining ring then press the crankshaft out of the closure plate (Fig. 7A–34). The bearing will stay on the shaft and can be pressed of f after the two snap rings are removed (Fig. 7A–35). Clean the bearing in clean solvent and allow to dry . Oil with engine oil and check the condition. Replace as needed.

A–02781

Fig. 7A–35 Installing Closure Plate

To check the crankshaft end play, use the following procedure: 1. Start with one white gasket (next to the block) then add one blue gasket (0.005” [0,127 mm]). (Or use the same sequence of gaskets as used during disassembly procedure).

2. Install the closure plate and tighten the four bolts to 30 ft.–lbs. (41 Nm) torque. Hit the end of the shaft with a soft hammer to make sure it is all the way down.

3. Mount the dial indicator (Fig. 7A–36), set the dial to zero and then place a screwdriver between the counterweight and the block. Pry the crankshaft toward the closure plate end and read the dial indicator . If the end play is not between 0.004–0.010” (0,101–0,254 mm) then go to step 4.

A–02782

Fig. 7A–36 Checking Crankshaft End Play

4. Remove the closure plate and add or remove gaskets to get the correct end play. Replace the closure plate, tighten the bolts to the correct torque, and repeat the end play check. Install the rear oil seal after the end play is correct.

Use a cylinder hone to hone the correct surface on the cylinder walls (Fig. 7A–34).

Check the clearance between the piston and cylinder wall. If it is over maximum, use an oversized piston.

Cross Hatch Pattern After Reboring

If the new main bearing inserts are installed in the block, push the bearing even with the outside surface of the block. Make sure the oil holes in the bearing are in alignment with the holes in the engine block.

PI–01907

Fig. 7A–37 Cylinder Hone 172 of 256

–7A–14–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

The engine uses a ball bearing which is located in the closure plate and on the crankshaft. If is not necessary to separate the crankshaft from the closure plate if the bearing turns easily on the shaft or there is no noise from the bearing.

Check the ring gap in the cylinder bore (Fig. 7A–38).

Install the rings on the pistons (Fig. 7A–39).

Install the piston and rod assembly and tighten the rod bolts to 200 in.–lbs. (23 Nm) torque.

PI–01904

Fig. 7A–38 Checking Ring Gap

Bevel Up

7A–10 CYLINDER HEAD

Bevel Down

Dealer Copy -- Not for Resale

Use a new gasket. Put the cylinder head in position and install the bolts. Make sure the washers are used. Tighten the bolts to 35 ft.–lbs. (48 Nm) torque in the correct sequence (Fig. 7A–40).

B–02284

Fig. 7A–39 Installing Rings 7A–11 INTAKE AND EXHAUST MANIFOLD Put a heavy flat washer or spacers on the manifold where the bolts are used to fasten the manifold and side panels to the engine block. Install the intake and exhaust and tighten the bolts to 25 ft.–lbs. (34 Nm) torque.

A–02678

Fig. 7A–40 Torque Sequence 7A–12 FLYWHEEL It is not necessary to remove the engine from the loader to remove the flywheel.

Remove the four (4) bolts and use a puller to removethe flywheel from the engine crankshaft.

Check the flywheel (Fig. 7A–41) for broken fins, cracks or keyway damage. Do not try to replace the ring gear on the flywheel. Y ou must replace the flywheel and ring gear as an assembly.

173 of 256

–7A–15–

B–02981

Fig. 7A–41 Engine Flywheel 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 174 of 256

–7A–16–

540, 543 Loader Service Manual

ENGINE SERVICE (543) Paragraph Number 7B–15 7B–10 7B–9 7B–7 7B–6

7B–30 7B–26 7B–26 7B–23 7B–19

7B–3 7B–16 7B–4 7B–2 7B–12 7B–13 7B–8 7B–5 7B–11 7B–1 7B–14

7B–9 7B–33 7B–17 7B–3 7B–27 7B–27 7B–23 7B–18 7B–27 7B–1 7B–28 Dealer Copy -- Not for Resale

ASSEMBLY OF THE ENGINE . . . . . . . . . . . . . . . . . . .

CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE, BLOWER HOUSING & RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MANIFOLD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PUMP & OIL FILTER ASSEMBLY . . . . . . . . . . . .

PISTONS & PISTON RINGS . . . . . . . . . . . . . . . . . . . . .

ROCKER ARMS & SHAFT . . . . . . . . . . . . . . . . . . . . . .

TIMING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page Number

543 ISUZU

WARNING

175 of 256

DO NOT service the Bobcat loader without instructions or taking the necessary safety precautions.

Before working on the loader , see the warnings and instructions at the beginning of this Service Manual.

After making the repair or adjustment, always check the function of the loader . Failure to obey warnings may cause injury or death.

–7B––1–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 176 of 256

–7B–0–

540, 543 Loader Service Manual

7B ENGINE SERVICE–543 LOADER (ISUZU) 7B–1 TROUBLESHOOTING The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

CAUSE

Slow cranking speed.

1, 2, 3, 4

Engine will not start.

5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 31, 32, 33

Difficult to start.

5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20,21, 22, 24, 29, 31, 32, 33

No power from the engine.

8, 9, 10, 11,12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 28, 29, 31, 32, 33

Engine is mis–firing.

8, 9, 10, 12, 13, 14, 16, 18, 19, 20, 25, 26, 28, 29, 31, 32, 33

Too much fuel consumption.

11, 13, 14, 16, 18, 20, 22, 23, 24, 25, 27, 28, 29, 31, 32, 33

Black exhaust.

11, 13, 14, 16, 18, 19, 20, 22, 24, 25, 27, 28, 29, 31, 32, 33

Blue/White Exhaust.

4, 16, 18, 19, 20, 25, 27, 31, 33, 34, 44, 53

Low oil pressure.

4, 35, 36, 37, 38, 39, 41, 42, 43, 55

Engine knocking.

9, 14, 16,18, 19, 22, 26, 28, 29, 31, 33, 35, 44, 45, 56

Engine running rough.

7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 23, 26, 28, 29, 30, 33, 44, 56

Vibration.

13, 14, 20, 23, 25, 26, 29, 30, 33, 44, 47

High oil pressure.

4, 37, 40

Overheating.

11, 13, 14, 16, 18, 19, 24, 25, 44, 46, 48, 49, 51

Too much crankcase pressure.

25, 31, 33, 34, 44, 52

Poor compression.

11, 19, 25, 28, 29, 31, 32, 33, 34, 45, 56

Start and stop.

10, 11, 12

177 of 256

–7B–1–

Dealer Copy -- Not for Resale

PROBLEM

540, 543 Loader Service Manual

7B–1 TROUBLESHOOTING (Cont’d)

1. Battery capacity low.

29. Sticking valves.

2. Bad electrical connection.

30. Incorrect high pressure tubelines.

3. Faulty starter motor.

31. Worn cylinder bores.

4. Incorrect grade of oil.

32. Worn valves and seats.

5. Low cranking speed.

33. Broken, worn or sticking piston rings.

6. Fuel tank empty.

34. Worn valve stems and guides.

7. Faulty stop control operation.

35. Worn or damaged bearings.

8. Plugged fuel line.

36. Not enough oil in the oil pan.

9. Faulty fuel lift pump.

37. Gauge is not correct.

10. Plugged fuel filter.

38. Oil pump is worn.

11. Restriction in the air cleaner.

39. Pressure relief valve is open.

12. Air in the fuel system.

40. Pressure relief valve is sticking closed.

13. Faulty fuel injection pump.

41. Broken relief valve spring.

14. Faulty fuel injectors.

42. Faulty suction valve.

15. Incorrect use of the glow plugs.

43. Plugged oil filter.

16. Faulty glow plugs.

44. Piston seizure.

17. Broken fuel injection pump drive.

45. Incorrect piston height.

18. Incorrect fuel pump timing.

46. Damaged fan.

19. Incorrect valve timing.

47. Faulty engine mounting.

20. Poor compression.

48. Faulty thermostat.

21. Plugged fuel tank vent.

49. Restriction in the water jacket.

22. Incorrect type or grade of fuel.

50. Plugged radiator.

23. Sticking or restricted throttle.

51. Faulty water pump.

24. Exhaust pipe restriction.

52. Plugged breather pipe.

25. Cylinder head gasket leaking.

53. Valve stem seals damaged.

26. Overheating.

54. Coolant level is low.

27. Cold running.

55. Plugged oil pump pipe screen.

28. Incorrect valve tappet adjustment.

56. Broken valve spring.

178 of 256

–7B–2–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

KEY TO CORRECT THE CAUSE

7B–2 FUEL SYSTEM 7B–2.1 Fuel Filter The fuel filter is located on the left side of the engine (Fig. 7B–1). T o replace the fuel filter, use the following procedure: 1. Close the shut–off valve at the fuel tank (Fig. 7B–2).

2. Remove the fuel filter element (Fig. 7B–1) by turning it counterclockwise.

3. Clean the filter housing where the element makes contact.

4. Put oil on the gasket of the fuel filter element.

B–05212

Fig. 7B–2 Fuel Tank Shut–off Fuel Filter B–02921

Fig. 7B–1 Fuel Filter

5. Install the fuel filter element and hand tighten only.

7. Remove the air from the fuel system.

Dealer Copy -- Not for Resale

6. Open the shut–off valve at the fuel tank (Fig. 7B–2).

B–05214

Fig. 7B–3 Injection Pump Vent

7B–2.2 Removing the Air from the Fuel System 1. Loosen the vent plug at the fuel injection pump (Fig. 7B–3).

2. Engage the starter and turn the engine until solid fuel flows from the vent port with no air bubbles.

3. Stop turning the engine. Tighten the vent plug.

4. Loosen the fittings at the fuel injectors (Fig. 7B–4).

5. Put the throttle at 1/2 open position.

6. Turn the engine with the starter until solid fuel flows from the high pressure tubeline fittings.

7. Tighten the high pressure tubeline fittings at the fuel injectors (Fig. 7B–4).

B–05216

Fig. 7B–4 Injector Fittings

7B–2.3 Fuel Lift Pump The fuel lift pump is located on the side of the injection pump (Fig. 7B–5). The lift pump can not be repaired. It is replaced as a complete assembly.

1. Disconnect the fuel lines to the lift pump.

2. Remove the bolts and remove the fuel lift pump.

3. Install a new gasket and the fuel lift pump.

4. Install the bolts and tighten.

B–05218

Fig. 7B–5 Fuel Lift Pump

5. Connect the fuel lines.

179 of 256

–7B–3–

540, 543 Loader Service Manual

7B–2.4 Removal of the Fuel Injection Pump The injection pump contains parts which have a very close tolerance and its operation has a direct effect on the performance of the engine.

IMPORTANT

If you do not have the correct equipment and trained personnel, adjustment or maintenance must not be done.

B–05222

Fig. 7B–6 High Pressure Lines 1. Remove the high pressure tubelines from the injection pump (Fig. 7B–6).

2. Remove the fuel lines to the injection pump (Fig. 7B–7).

4. Disconnect the return spring at the fuel injection pump (Fig. 7B–9).

5. Disconnect the throttle linkage.

6. Remove the six (6) bolts which hold the injection pump to the timing cover (Fig. 7B–10).

B–05219

Fig. 7B–7 Fuel Lines

B–05220

Fig. 7B–8 Fuel Lines

7. Remove the injection pump (Fig. 7B–11) from the engine.

7B–2.5 Fuel Injection Pump Drive Gear

B–05221

Fig. 7B–9 Return Spring

B–05223

Fig. 7B–10 Mounting Bolts

1. Remove the nut and lockwasher from the injection pump shaft (Fig. 7B–12).

2. Use a puller to remove the gear.

3. To install the gear, install the key and make alignment of the key with the keyway in the gear and install the gear on the injection pump shaft.

4. Install the lockwasher and nut.

5. Tighten the nut to 40 ft.–lbs. (54 Nm) torque.

180 of 256

B–02982

Fig. 7B–11 Removing Pump –7B–4–

B–02979

Fig. 7B–12 Pump Drive Gear 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

3. Disconnect the fuel lines from the fuel pump (Fig. 7B–8).

7B–2.6 Installation and Timing of the Fuel Injection Pump 1. Remove the cover on the timing case.

2. Turn the engine so that the “Z” mark on the gear can be seen in the hole in the timing case (Fig. 7B–13).

3. Install the injection pump.Make sure the “Z” mark on the injection pump gear is in correct alignment with the “Z” mark of the drive gear (Fig. 7B–13).

A–02720

Fig. 7B–13 Timing Marks

B–05225

Fig. 7B–14 Flange Timing Mark

4. Install the six (6) mounting bolts (in the timing case) and tighten to 12 ft.–lbs.

(16 Nm) torque.

5. Install the cover over the hole in the timing case.

7. Connect the throttle to the injection pump.

8. Connect the return spring (Fig. 7B–9).

9. Connect the fuel lines at the fuel lift pump (Fig. 7B–8).

10. Install the fuel line at the injection pump (Fig. 7B–7).

IMPORTANT

Dealer Copy -- Not for Resale

6. Check the timing mark on the injection pump flange (Fig. 7B–14). If the timing marks are not in alignment, loosen the three (3) bolts (Fig. 7B–15) and make alignment of the timing marks (Fig. 7B–14).

B–05224

Fig. 7B–15 Pump Mounting Nuts

If you do not have the correct equipment and trained personnel, adjustment or maintenance must not be done.

11. Connect and tighten the high pressure tubelines (Fig. 7B–6).

7B–2.7 Fuel Injection Pump Reservoir The oil in the reservoir must be checked every 100 hours of operation.

To check the level in the reservoir, use the following procedure: 1. Remove the check plug (Fig. 7B–16) at the side of the fuel injection pump.

B–05226

Fig. 7B–16 Pump Check Plug 181 of 256

–7B–5–

540, 543 Loader Service Manual

2. If no oil can be seen at the port, remove the breather on the top of the fuel injection pump (Fig. 7B–17).

3. Add the same type of oil that is being used in the engine (See the Oil Specifications Chart in Section 1). Add oil until it flows from the check port.

4. Install the plug (Fig. 7B–16) and tighten.

7B–2.8 Fuel Injector Nozzles

B–05227

Fig. 7B–17 Breather Cap

Dealer Copy -- Not for Resale

WARNING

Diesel fuel under pressure can have enough force to penetrate the skin.

Check to be sure all connections are tight and the lines, pipes and hoses are not damaged before you disconnect any lines. Often you cannot see fuel leakage from a small hole. Use a piece of cardboard or wood to find leakage. See a doctor immediately if you get injured from diesel fuel. Serious problems can result if you do not get immediate medical attention.

These are some of the engine problems caused by injector nozzles which have a defect: 1. The engine is hard to start or will not start.

2. Rough engine operation.

B–05228

3. The engine will not idle correctly.

Fig. 7B–18 Pump Drain Port

4. The engine will not have full power.

5. The engine exhaust smoke is black, white or blue.

Remove the injector nozzles from the engine and test them only after the engine performance shows a defect.

Removing Nozzles

the Fuel Injector

1. Remove the fuel return lines from the injector nozzles (Fig. 7B–19).

2. Remove the high pressure tubelines (Fig. 7B–20).

182 of 256

B–05229

Fig. 7B–19 Injectors Return Line –7B–6–

B–05215

Fig. 7B–20 Injector High Pressure Line 540, 543 Loader Service Manual

5. Remove the fuel injector nozzle from the engine (Fig. 7B–21).

IMPORTANT

Do not disassemble or test the injector nozzles unless you have the correct service and testing tools.

Checking the Fuel Injector Nozzles

B–05230

The tools listed will be needed to do the following procedure:

Fig. 7B–21 Fuel Injectors

MEL–10018 – Injection Nozzle Tester MEL–10019 – Accessory Set 1. Connect the injector nozzle to the tester with the nozzle in a down position (Fig. 7B–22).

Dealer Copy -- Not for Resale

2. Slowly operate the hand lever of the test pump until the injector nozzle valve opens. The working pressure for the nozzle is as listed: (a) Working Pressure 0 1707 PSI (11770 kPa) 3. If the pressure is not correct, clean and adjust the nozzle.

4. Check for inside leakage. Operate the hand lever until the pressure is almost enough to open the injector valve. Make a record of the pressure.

5. Release the hand lever. Check the pressure decrease for six (6) seconds.

The injector nozzle has a defect if the pressure decrease is more than 740 PSI (5162 kPa) in the six (6) seconds.

A–02513

Fig. 7B–22 Testing the Nozzle

WARNING

Keep away from fuel coming from the nozzles. Wear eye protection.

CORRECT

WRONG

6. Check the spray pattern of the nozzle for the following conditions (Fig. 7B–23): (a) Does not come out the side of the nozzle. (b) Does not have drops coming from the nozzle. (c) Does not have a flow (solid stream) coming from the nozzle.

Any of the above conditions show a defect or a dirty injector nozzle. Clean the nozzle and make the test again. Replace the injector nozzle that does not operate correctly after they have been cleaned.

183 of 256

–7B–7–

A–02621

Fig. 7B–23 Spray Pattern 540, 543 Loader Service Manual

Disassembly of the Fuel Injector Nozzle 8

1. Fasten the body of the nozzle holder (Fig. 7B–24, Item 1) in a vise and remove the cap nut (Item 2), be careful not to put a scratch on the nozzle holder.

9

10

1

6

5

3 4

2

12

11 2. Remove the nut and adjustment bolt (Fig. 7B–24), Items 3 & 4) and take out the washers (Item 5), nozzle spring (Item 6) and the push rod (Item 7).

7

13 C–02345

Fig. 7B–24 Nozzle and HolderAssembly

3. Remove the nozzle nut (Fig. 7B–24, Item 8) and take out the nozzle assembly (Item 9), then remove the bushing (Item 10). Keep the nozzle assembly in clean diesel fuel.

Dealer Copy -- Not for Resale

4. Remove the inlet connector assembly (Fig. 7B–24, Item1) 1 together with the gasket (Item 12) and take out the edge filter (Item 13).

Inspection of the Fuel Injector Nozzle 1. Wash the needle valve and nozzle body in the clean solvent. T ilt the body to an angle of 60° from vertical and check that the needle valve slides out smoothly. If the needle valve is not free or if its sliding movement is very loose, replace the nozzle assembly. (a) Check the seat area and the tip of the needle valve for wear . Replace the nozzle if it is worn.

2. Nozzle holders. (a) Check the thread areas of the nozzle holders for wear or damage.

Replace nozzle assembly if a defect is found. (b) Check the nozzle springs for weak condition, corrosion or damage. (c) Check the push–rods for bending and the surface in contact with the needle valve for wear and magnet effect. (d) Check the upper surface and needle valve seat on the nozzle body for wear or scratch marks.

Assembling the Fuel Injectors Nozzle Assemble the fuel injector nozzle in the reverse order of disassembly and make note of the following items.

1. Wipe and clean the contact areas of the nozzle and body of the nozzle holders to remove any oil. Install the nozzle into the body of the nozzle holder and tighten the nozzle nut.

2. Install new gaskets at the time of assembly.

184 of 256

–7B–8–

540, 543 Loader Service Manual

Installation of the Fuel Nozzles

Injector

1. Install the fuel injector nozzle in the engine cylinder head. Make sure to install the washer under the nozzle tip (Fig. 7B–25).

B–05231

2. Tighten the fuel injector nozzle (Fig. 7B–26).

Fig. 7B–25 Installing Fuel Injector Nozzle

B–05230

Fig. 7B–26 Tightening Fuel Injectors

4. Install the return lines on the fuel injector nozzles (Fig. 7B–28).

B–05215

Fig. 7B–27 Injector High Pressure Lines

Dealer Copy -- Not for Resale

3. Install the high pressure tubelines and tighten (Fig. 7B–27).

B–05229

Fig. 7B–28 Injector Return Lines

7B–3 ENGINE, BLOWER HOUSING AND RADIATOR 7B–3.1 Removing the Housing

Blower

1. Remove all the bolts from around the outside edge of the blower housing (Fig. 7B–29).

2. Remove the nut from the bolt that holds the wiper in position (Fig. 7B–30).

185 of 256

B–05232

Fig. 7B–29 Blower Housing Bolts –7B–9–

B–05233

Fig. 7B–30 Wiper Bolt 540, 543 Loader Service Manual

3. Remove the outer housing from the blower (Fig. 7B–31).

B–05235

4. Remove the wiper and bushing from the bolt (Fig. 7B–32).

Fig. 7B–32 Removing Wiper & Bushing

B–05234

5. Remove the bolts from the blower fan (Fig. 7B–33).

B–05236

Fig. 7B–33 Blower Fan Bolts

6. Remove the blower fan from the crankshaft sheave (Fig. 7B–34).

B–05237

Fig. 7B–34 Removing Blower Fan 7. Remove the nuts and bolts from the mounting plate for the blower housing (Fig. 7B–35).

8. Remove the bolt for the mounting plate bracket at the right side of the engine (Fig. 7B–36).

186 of 256

B–05238

Fig. 7B–35 Mounting Plate Bolts –7B–10–

B–05239

Fig. 7B–36 Mounting Plate Side Bolt 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

Fig. 7B–31 Outer Blower Housing

9. Remove the mounting plate from the engine (Fig. 7B–37).

7B–3.2 Removing the Engine

Lift the loader and put jackstands under the loader frame so there is no danger of the loader falling and causing personal injury.

B–05240

Fig. 7B–37 Removing Mounting Plate

B–05243

Fig. 7B–38 Removing Coolant

1. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).

Dealer Copy -- Not for Resale

2. Remove the rear door (See Paragraph 5–4, Page 5–9).

3. Remove the battery from the loader (See Paragraph 6–3.1, Page 6–3).

4. Remove the blower housing (See Paragraph 7B–3.1).

5. Disconnect the engine wiring harness.

6. Disconnect the wires from the alternator.

7. Disconnect the ground wire at the right side of the engine.

8. Remove the bolts which hold the hydrostatic pumps and engine together.

9. Disconnect the throttle linkage at the injection pump.

10. Remove the radiator hose at the radiator (Fig. 7B–38) and remove the coolant from the system.

B–05246

Fig. 7B–39 Removing Radiator Hose

11. Loosen the clamps on the radiator hose and remove the hose from the thermostat housing and radiator (Fig. 7B–39).

12. Remove the support brackets (both sides) from the radiator air shrouding (Fig. 7B–40).

13. Remove the plate (Fig. 7B–41, Item 1) from the air shrouding and remove the air shrouding from the engine (Fig. 7B–41).

B–05241

Fig. 7B–40 Air Shrouding Bracket 187 of 256

–7B–11–

B–05251

Fig. 7B–41 Air Shrouding & Plate 540, 543 Loader Service Manual

14. Remove the clamp at the exhaust pipe (Fig. 7B–42).

15. Remove the exhaust pipe from the muffler and from the loader (Fig. 7B–43).

16. Remove the air cleaner hose (Fig. 7B–44).

17. Disconnect the fuel return line (Fig. 7B–45).

B–05248

Fig. 7B–42 Air Cleaner Hose

18. Remove the bolts from the engine mounting brackets (both sides) (Fig. 7B–46).

B–05247

Fig. 7B–43 Removing Exhaust pipe

19. Install an engine removal table (Fig. 7B–47, Item 1) at the rear of the loader.

7B–3.3 Installing the Engine 1. Slide the engine into the rear of the loader until the engine makes contact with the hydrostatic pump coupler.

Dealer Copy -- Not for Resale

20. Slide the engine toward the rear of the loader and on the table (Fig. 7B–47).

B–05250

Fig. 7B–44 Air Cleaner Hose

2. Make alignment of the engine splines to the coupler and slide the engine into the correct location.

3. Remove the engine removal table (Fig. 7B–47, Item 1).

4. Install the bolts in the engine mounting brackets and tighten to 65–70 ft.–lbs. (88–95 Nm) torque.

B–05252

Fig. 7B–45 Fuel Line

5. Connect the fuel line (Fig. 7B–45).

6. Install the air cleaner hose (Fig. 7B–44) and tighten the clamps.

7. Install the exhaust into the loader and on the muf fler (Fig. 7B–43).

8. Tighten the exhaust pipe clamp (Fig. 7B–42).

188 of 256

B–05319

B–05249

Fig. 7B–46 Engine Mounting –7B–12–

Fig. 7B–47 Engine Removal 540, 543 Loader Service Manual

9. Install the air shrouding in the loader and install theplate in the air shrouding (Fig. 7B–41).

10. Install the support brackets and tighten the bolts (both sides) (Fig. 7B–40).

11. Install the radiator hose on the thermostat housing and the radiator (Fig. 7B–39) and tighten the clamps.

12. Install the other radiator hose to the radiator and tighten 7B–38).

the clamp (Fig.

13. Connect the throttle linkage to the fuel injection pump.

14. Install the bolts which hold the hydrostatic pump and engine together and tighten to 65–70 ft.–lbs. (88–95 Nm) torque.

B–05240

Fig. 7B–48 Installing Mounting Plate

15. Connect the ground wire, alternator wires and the engine harness connector.

Dealer Copy -- Not for Resale

16. Install the blower housing (See Paragraph 7B–3.4).

17. Install the battery (See Paragraph 6–3.3, Page 6–4).

18. Install the rear door (See Paragraph 5–4, Page 5–9).

19. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).

20. Remove the jackstands from under the loader frame.

7B–3.4.Installing Housing

the

Blower

1. Install the mounting plate on the engine (7B–48).

B–05239

Fig. 7B–49 Mounting Plate Side Bolt

B–05238

Fig. 7B–50 Mounting Plate Bolts

2. Install the bolt for the mounting plate at the right side of the engine and tighten (Fig. 7B–49).

3. Install the bolts and nuts for the mounting plate and tighten.

4. Install the blower fan on the crankshaft sheave (Fig. 7B–51).

5. Install the bolts in the blower fan and tighten (Fig. 7B–52).

189 of 256

B–05237

Fig. 7B–51 Installing Blower Fan –7B–13–

B–05236

Fig. 7B–52 Blower Fan Bolts 540, 543 Loader Service Manual

6. Install the bushing and wiper on the bolt (Fig. 7B–53).

7. Install the outer housing for the blower housing on the mounting plate (Fig. 7B–54).

B–05235

Fig. 7B–53 Installing Wiper and Bushing

B–05234

Dealer Copy -- Not for Resale

Fig. 7B–54 Installing Blower Housing

8. Install the bolts and nuts and tighten (Fig. 7B–55 & 7B–56).

B–05233

Fig. 7B–55 Wiper Bolt

B–05232

Fig. 7B–56 Blower Housing Bolts

7B–3.5 Removing the Radiator

1. Remove the blower housing (See Paragraph 7B–3.1).

2. Remove the radiator cap from the radiator (Fig. 7B–57).

190 of 256

B–05253

Fig. 7B–57 Radiator Cap –7B–14–

B–05243

Fig. 7B–58 Removing Coolant 540, 543 Loader Service Manual

3. Remove the radiator hose from the radiator and remove the coolant (Fig. 7B–58).

4. Remove the radiator hose from the thermostat housing and the radiator (Fig. 7B–59).

B–05246

Fig. 7B–59 Removing Radiator

Dealer Copy -- Not for Resale

5. Remove the support brackets (both sides) from the radiator air shrouding (Fig. 7B–60).

B–05241

Fig. 7B–60 Air Shrouding Bracket

6. Remove the plate (Fig. 7B–61, Item 1) from the air shrouding and remove the air shrouding from the engine (Fig. 7B–61).

B–05251

Fig. 7B–61 Air Shrouding & Plate

7. Loosen the exhaust pipe clamp and remove the exhaust pipe from the muffler and the loader (Fig. 7B–62).

8. Remove the bolts (both sides) for the radiator mounting plate (Fig. 7B–63).

191 of 256

B–05247

Fig. 7B–62 Exhaust Pipe –7B–15–

B–5254

Fig. 7B–63 Mounting Plate Side Bolts 540, 543 Loader Service Manual

9. Remove the nuts (both sides) at the front of the radiator mounting plate (Fig. 7B–64).

10. Remove the bolts (both sides) at the front of the radiator and the mounting plate (Fig. 7B–65).

11. Pull the mounting plate and the radiator assembly down until it makes contact with the engine.

12. Lift the radiator up and out of the mounting plate (Fig. 7B–66).

B–05320

Fig. 7B–64 Mounting Plate Nuts

7B–3.6 Installation of the Radiator

2. Push the radiator and mounting plate assembly up into position. Make sure the holes are in correct alignment.

3. Install the mounting plate bolts (one on each side) and the nuts (one on each side at the front) and tighten (Fig. 7B–63 & 7B–64).

B–05321

Fig. 7B–65 Radiator Mounting 4. Install the radiator mounting bolts and tighten (Fig. 7B–65).

5. Install the exhaust pipe in the loader and on the muf fler and tighten the clamp (Fig. 7B–62).

6. Install the air shrouding in the loader and the plate on the air shrouding (Fig. 7B–61).

7. Install the support brackets for the air shrouding and tighten the bolts (Fig. 7B–60).

8. Install the radiator hose on the thermostat housing and the radiator and tighten the clamps (Fig. 7B–59).

9. Install the radiator hose on the other side and tighten the clamp.

10. Install the blower housing (See Paragraph 7B–3.4).

11. Put the correct amount of coolant in the radiator (See Section 8 for capacity) and install the radiator (Fig. 7B–57).

192 of 256

B–05322

Fig. 7B–66 Radiator Assembly –7B–16–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

1. Install the radiator on the mounting plate (Fig. 7B–66).

7B–4 ENGINE OVERHAUL 7B–4.1 Disassembly of the Engine 1. Remove the engine from the loader (See Paragraph 7B–3.2).

2. Remove the fuel injection pump (See Paragraph 7B–2.4) (Fig. 7B–67).

3. Remove the bolts which hold the fuel filter and remove the fuel assembly.

filter

4. Remove the fuel injectors nozzles (See Paragraph 7B–2.8).

B–02982

Fig. 7B–67 Removing Injection Pump

5. Remove the oil filter assembly and disconnect the tubelines that goes to the rocker arm shaft for oil pressure.

6. Remove the sender switch for the oil pressure. and lower mounting bracket and

Dealer Copy -- Not for Resale

7. Remove the bolts for the adjustment remove the alternator.

8. Remove the bolts that hold the starter and remove the starter from the engine.

B–02837

9. Remove the muffler and manifold assembly.

Fig. 7B–68 Removing Sheave

10. Remove the bolts which hold the water pump and remove the water pump.

11. Bend the washer on the bolt for the crankshaft sheave.

12. Remove the crankcase and oil pan together . If the crankcase will not separate from the block, use a screwdriver and pry them apart (Fig. 7B–70).

13. Remove the timing gear cover.

14. Remove the idler gear.

B–2838

Fig. 7B–69 Removing Rocker Arm 15. Remove the valve cover.

16. Remove the rocker arm assembly from the engine (Fig. 7B–69).

NOTE: Turn each bolt in the rocker arm assembly 1/4 turn until all the bolts are loose.

17. Remove the push rods from the engine.

NOTE: Turn each bolt in the cylinder head 1/4 turn at a time until all the bolts are loose.

18. Remove the cylinder head and gasket.

19. Remove the crankcase and oil pan together . If the crankcase will not separate from the block, use a screwdriver and pry them apart (Fig. 7B–70).

193 of 256

–7B–17–

B–2826

Fig. 7B–70 Removing Oil Pan 540, 543 Loader Service Manual

20. Disconnect the pipe at the connection on the cylinder body side.

21. Remove the bolts and remove the oil pump assembly from the engine block.

22. Remove the bolts from the thrust plate of the camshaft and remove the camshaft (Fig. 7B–71).

NOTE: Be careful not to scratch the camshaft bearings.

Magnet Tappet B–02833

Fig. 7B–71 Removing Camshaft

C–2341

Fig. 7B–72 Removing Tappets

23. Remove the front plate fromthe engine.

24. Use a magnetic tool to remove the tappets from the engine block 7B–72).

(Fig.

NOTE: Remove the carbon from the upper part of the cylinder wall before removing the piston and rod assembly. being

26. Remove the connecting rod caps and push the piston and rod assembly through the top of the engine block (Fig. 7B–73).

27. Remove the flywheel (See Paragraph 7B–16.1, Page 7B–33).

B–02835

Fig. 7B–73 Removing Pistons

28. Mark the main bearing caps so that each will be installed in the correct location.

NOTE: Do not cause damage to the oil seal in the cap for the rear main bearing.

29. Remove the main bearing caps and bearings.

30. Remove the thrust washers and the crankshaft (Fig. 7B–74).

31. Wash and clean all the parts to remove dirt, carbon, oil, grease or rust.

32. Inspect the cylinder body and the cylinder head for damage.

33. Clean all the oil openings with compressed air and check that each opening has no restriction.

B–2834

Fig. 7B–74 Removing the Crankshaft

34. Remove the carbon from the pistons, cylinder head and valves.

7B–5 ROCKER ARMS AND SHAFT 7B–5.1 Disassembly of the Rocker Arms 1. Remove the snap ring from each end of the rocker arm shaft.

2. Remove the springs, rocker arms, rocker shaft bracket and rocker shaft (Fig. 7B–75).

3. Keep all parts in correct order for correct assembly.

4. Assemble the parts in the reverse order of disassembly.

194 of 256

–7B–18–

A–02512

Fig. 7B–75 Removing Rocker Arm 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

25. Mark each piston so it will be returned to its original location when assembled.

7B–5.2 Inspection of the Rocker Arms 1. Measure the outside diameter of the rocker shaft with a micrometer (Fig. 7B–76).

2. Replace the rocker shaft if measurement is over the limit (See Section 8 for specifications).

A–02510

Fig. 7B–76 Measuring Shaft

A–02520

Fig. 7B–77 Rocker Arm

4. Check the wear of the face of the rocker arms that are in contact with the valve stem.

Replace the rocker arms if the amount of wear is over maximum. Remove the small scratch marks on the face of the rocker, by grinding (Fig. 7B–78).

A–02524

Fig. 7B–78 Grinding Rocker Arm

Dealer Copy -- Not for Resale

3. Measure the inside diameter of the bushings with a micrometer.

Install new bushings if the measurements are over the limit (Fig. 7B–77).

B–02849

Fig. 7B–79 Removing Valve Springs

7B–6 CYLINDER HEAD 7B–6.1 Disassembly of the Cylinder Head 1. Disconnect the glow plug wiring at the connectors and remove the glow plugs from the cylinder head.

2. Mark the valves so that each will be installed in their original location.

3. Use a valve spring compressor to remove the valve springs and remove the split collar, valve springs and valve (Fig. 7B–79).

B–2848

Fig. 7B–80 Removing Valve Guides

4. Remove the valve seals from the valve guides.

5. Use a tool to force the valve guides out toward the bottom of the cylinder head (Fig. 7B–80).

NOTE: If the hot plugs are to be removed, do steps 6 through 8.

6. Put a cylinder number on each of the hot plugs.

7. Put a 1/4” (5–7 mm) diameter rod into the nozzle hole in the cylinder head.

Use a hammer to force the hot plug out (Fig. 7B–81).

NOTE: Hold the rod so that it is against the upper edge of the hole with threads, as shown in figure 7B–81.

8. Do not hit the hot plug with the rod, or damage to the heat shield can result.

195 of 256

–7B–19–

B–03003

Fig. 7B–81 Removing Hot Plug 540, 543 Loader Service Manual

7B–6.2 Inspection of the Cylinder Head 1. Carefully remove carbon from the bottom of the cylinder head (Fig. 7B–82).

Check the cylinder head for cracks and damage.

be

2. Check the lower surface of the cylinder head for distortion, in six (6) directions, using a straight edge and a feeler gauge. If the amount of the distortion is more than 0.008” (0,2 mm), correct by grinding, so that the maximum amount of distortion is within 0.0012” (0,05 mm).

3. Check the joining face of the intake and exhaust manifolds for distortion, using the same method as for checking the cylinder head. If the amount of distortion is more than 0.016” (0,4 mm), correct by grinding so that maximum amount of distortion is within 0.0012” (0,05 mm).

A–02521

Fig. 7B–82 Removing Carbon

Clearance

7B–6.3 Inspection of the Combustion Chambers 1. Remove all the carbon from the combustion chambers. Check the heat shield and hot plug holes in the combustion chamber, for damage.

PI–02096

Fig. 7B–83 Checking Valve Stem Wear

2. Check the hot plug fitting areas for cracks and damage and make replacement of the cylinder head assembly if there is any damage condition to the cylinder head. High spots or pieces on the hot plug seat can cause poor fitting of the hot plug.

7B–6.4 Inspection and Correction of the V alves & Guides 1. Check the amount of wear of the valve stems in the valve guides (Fig. 7B–83).

2. Use a micrometer to measure the outside diameter of the valve stem at locations “A”, “B” & “C” (Fig. 7B–84).

3. Check the valve seats for the wrong contact or damage and correct or replace as needed.

Before correcting the valve seat, check the valve guide and install a new guide as necessary.

196 of 256

Valve Stem End

PI–02095

Fig. 7B–84 Valve Stem Measurements –7B–20–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

NOTE: When removing carbon from the bottom of the cylinder head, careful not to scratch the valve seat area.

4. Cut the valve seat using a seat cutter of the correct specifications so that the contact width is correct (Fig. 7B–85 & 7B–86).

45°

NOTE: When cutting the valve seat use a guide rod of the correct diameter.

150° 90° 30°

Contact Width

Valve Guide Must Be Free from Wear, Inclination and Out–of–Round

PI–2095

5. If the amount of valve seat depth is over the limit for being repaired, replace the valve seat insert (Fig. 7B–87).

Fig. 7B–85 Valve Seat Cutter

PI–02098

Fig. 7B–86 Valve Seat Angles

Depression

(a) Use a torch to heat the opposed two (2) sides of the inner face of the valve seat red Fig. 7B–87 Checking Valve Seat Depth hot. Let the insert cool for 3–5 minutes. Use a screwdriver to remove the valve seat insert.

Dealer Copy -- Not for Resale

6. Use the following procedure for replacement of the valve seat insert:

PI–02092

7. Press the insert all the way into the insert bore. Then grind the seat face.

8. Check the head and stem of the intake and exhaust valves for wear and distortion and replace as needed. Also check and install new valves if the thickness of the valve head is less than the limit (Fig. 7B–88).

Thickness of Valve Head PI–02101

Fig. 7B–88 Checking New Valve

9. Use a valve grinder to correct the seat face of the valves to an angle of45°.

Correct the valve stem end as needed.

10. Put valve grinding compound on the seat face of the valve and use a grinding tool to check the valve face to seat contact.

NOTE: Contact width which is too wide will cause carbon deposits between valve and seat. Contact width which is too narrow will increase the wear of the parts.

197 of 256

–7B–21–

B–02851

Fig. 7B–89 Grinding Valve Seat 540, 543 Loader Service Manual

7B–6.5 Inspection of the V Springs

alve

1. Make a visual check of the valve springs for damage. Put the valve springs on a surface plate and check the amount of deviation of the valve spring from vertical, using a square.

Install a new spring if the amount of deviation from vertical is over the limit (Fig. 7B–90).

Free Length

2. Check the tension of the valve springs with a spring tester .

Install new valve springs if the measured value is over the limit (Fig. 7B–91).

A–02525

Fig. 7B–91 Valve Spring Tension

PI–02119

Fig. 7B–90 Checking Valve Springs

1. Check the push rods for wear or bending. Replace worn orbend push rods.

2. Check the face of the tappets in contactwith the push rods for wear. Replace any tappets which have a defect.

3. Measure the outside diameter of the tappets with a micrometer. Install new tappets if the amount of reduction in the outside diameter is over the limit (Fig. 7B–92).

A–02511

Fig. 7B–92 Checking Valve Tappet

7B–6.7 Installation of the Hot Plugs 1. Align the round part of the hot plug with a groove in the cylinder head and install the hot plug into position by hitting the circumference of the hot plug carefully with a brass hammer.

2. Hold a soft metal plate with smooth surface on the hot plug to protect the face of the hot plug from damage.

3. Use a hydraulic press to press the hot plug fully into position slowly.

Flush

B–03004

Fig. 7B–93 Fitting New Hot Plug

4. After the new hot plug has been installed, grind the end of the hot plug until it is even with the cylinder head face (Fig. 7B–93).

7B–6.8 Assembly of the System

Valve

1. Push the valve guide into position from the upper face of the cylinder head (Fig. 7B–94 & 7B–95).

198 of 256

PI–02099

Fig. 7B–94 Valve Guide Location (Cross Section) –7B–22–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

7B–6.6 Inspection of the Push Rods and T appets

2. Install the oil seal on the valve guide.

NOTE: Install the oil seal carefully, to prevent damage.

3. Install the valve springs and valve spring seat.

4. Compress the valve springs with the valve spring compressor and install the locks for the valve stem.

5. Install the manifold gasket and the manifold assembly.

B–02846

Fig. 7B–95 Installing Oil Seal

7B–7 CYLINDER BLOCK 7B–7.1 Inspection of the Cylinder Block 1. Check the cylinder block for cracks by magnetic or red color method (Fig. 7B–96).

2. Check the distortion of the cylinder block surface using the following specifications: (a) Standard Valve . . . . . . . . . . . . . . . . . . . . . . . .Below .

0.002” (0,05 mm)

Dealer Copy -- Not for Resale

(b) Valve for Need of Servicing . . . . . . . . . . . . . . . .Below 0.008” (0,2 mm)

7B–7.2 Correction of the Cylinder Bores 1. Use a cylinder bore gauge to measure the cylinderbore at the upper, middle and lower locations of the cylinder in two directions: (1) In line with the crankshaft; and (2) At a right angle to the crankshaft.

2. Cut the cylinders to oversize if the amount of wear is over the standard valve, or if the cylinder wall is damaged.

3. When the measurements are taken, find the piston oversize according to the largest bore diameter. Use a micrometer to measure the outside diameter of the pistons at the base, in the direction of the side thrust, at normal room temperature.

C–02340

Fig. 7B–96 Checking Cylinder Block

4. To find the bore diameter needed for hone operation, use the following formula: Cylinder bore diameter after hone operation=P+C–H+E P: Piston outside diameter C: Piston clearance H: Amount for hone operation E: Error in bore finish 5. Measure the cylinder bore diameter after hone operation is complete.

NOTE: Cylinder bores, after hone operation, must be (0,02 mm) of each other.

held within 0.008”

7B–8 PISTONS AND PISTON RINGS 7B–8.1 Disassembly of the Piston and Rings 1. Use a piston ring expander tool to remove the piston rings from the piston.

199 of 256

–7B–23–

540, 543 Loader Service Manual

2. Use a snap ring pliers to remove the piston pin snap ring (Fig. 7B–97).

3. Heat the piston to 120°–140°F. (50–60°C.) and remove the piston pin (Fig. 7B–98).

NOTE: Keep the piston, piston pin and connecting rod from each cylinder in separate groups in the sequence of the cylinder numbers, make sure that they are installed in their original locations.

B–03012

Fig. 7B–97 Piston Snap Ring

A–02530

Fig. 7B–98 Removing Piston Pin

7B–8.2 Inspection of the Pistons

2. Use an outside micrometer to measure the outside diameter of the pistons at the base, at a right angle to the piston pin hole. Measure the cylinder bore diameter at the base of the piston with a cylinder bore gauge. Then, compare the measured values to find the piston clearance. The standard clearance is 0.004”–0.005” (0,104–0,124 mm).

A–02519

Fig. 7B–99 Piston Ring Gap NOTE: When installing new piston rings on the pistons without cutting new cylinder sizes, measure the piston ring gaps with the piston rings held at the lower point of the cylinder (Fig. 7B–99).

3. Use a feeler gauge to measure the clearance between the piston ring and the ring groove in the piston. T ake a measurement at several locations around the circumference of the piston (Fig. 7B–100).

7B–8.3 Inspection of the Connecting Rods & Bearings 1. Check the connecting rods for bending, distortion and damage.

A–02526

Fig. 7B–100 Piston Ring Clearance

2. Check for alignment between the big and the small end (Fig. 7B–101).

3. If the amount of wrong alignment or distortion is servicing, correct or replace the connecting rod.

over the value limit for

4. The normal clearance between the piston and the small end bushing is such that the lubricated piston pin can be pushed into the bushing with finger pressure. Replace either the piston pin or bushing if the pin fits too loosely into the bushing.

Standard Clearance . . . . . . . . . . . . . . . . . . . . . .Below .

0.0005” (0,013 mm) Limit for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Below .

0.002” (0,.05 mm) 200 of 256

–7B–24–

B–02992

Fig. 7B–101 Connecting Rod Alignment 540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

1. Make a visual check of the pistons for scratches, cracks or seizure and replace any found to have a defect.

5. Assemble the connecting rod on the crankshaft and use a feeler gauge to measure the side clearance between the connecting rod big end and the crankpin (Fig. 7B–102). Replace the connecting rod if the clearance is over the limit.

Standard Clearance . . . . . . . . . . . . . . . . . . . . 0.008–0.010” .

(0,2–0,25 mm) Limit for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Above ..

0.014” (0,35 mm) 6. When a new bushing is fitted into the connecting rod small end, make the inner face smooth with a reaming tool according to the piston pin diameter.

7. When installing a new connecting rod, piston or piston pin, measure the weight of the replacement parts. Make necessary adjustment by grinding or selection of parts so that the weight of each piston and connecting rod assembly is held within 15 grams of each other (Fig. 7B–103).

B–03013

Fig. 7B–102 Checking Side Play

7B–8.4 Assembly of the Piston & Connecting Rod

Dealer Copy -- Not for Resale

1. Heat the piston to about 190–250°F. (70–120°C.) Align the small end hole of the connecting rod with the piston pin hole and install the piston pin.

NOTE: Assemble the connecting rod with the piston so that the side of the connecting rod with the cylinder number mark is toward the camshaft side of the engine.

A–02509

2. Install the snap rings.

Fig. 7B–103 Checking Weight

3. Use a ring expanding tool to assemble the piston rings on the piston (Fig. 7B–104).

NOTE: The first compression ring is chamfered. Install the third compression ring with the under cut side down. Install the first oil ring to the piston with the expander ring.

7B–8.5 Inspection of the Connecting Rod Bearings 1. Check the connecting rod bearings for wear, poor contact, sign of seizure or loss of tension and replace if defect is found.

A–02507

2. Install the connecting rod bearing and the bearing cap and tighten the bearing cap bolts to a torque of 58 ft.–lbs. (79 Nm). Then, measure the inside diameter of the bearing with an inside micrometer (Fig. 7B–105).

Fig. 7B–104 Piston Rings

3. If the oil clearance has increased because of wear in the crankpins, cut to a smaller size and install smaller size connecting rod bearings.

4. To measure the oil clearance, use the following procedure: (a) Wipe clean the bearings and crankpins to remove oil. (b) Install a piece of plasti–gauge over the direction of the axis of the crankshaft.

crankpin or bearing in the

(c) Install the connecting rod bearing cap and tighten the cap bolts to the correct torque.

201 of 256

–7B–25–

B–02991

Fig. 7B–105 Measuring Rod Bearing 540, 543 Loader Service Manual

NOTE: Do not move the crankshaft or connecting rods when making this check. (d) Remove the bearing cap bolts and bearing cap. (e) Check the width of the plasti–gauge against the scale printed on the instructions (Fig. 7B–106).

NOTE: Never try to file the bearings or install shims to adjust the oil clearance. Make sure the oil clearance is within specifications before installing the bearings. Make sure to get the correct size bearings if the crankshaft is cut under size.

A–02527

Fig. 7B–106 Checking Plastic Gauge 7B–9 CRANKSHAFT 7B–9.1 Inspection of the Crankshaft and Bearings 1. Check the crankshaft bearings and install them using the same method as used for installing and checking the connecting rod bearings. size indicated in specifications when

3. Visually check the crank journals, crankpins and oil seal fitting surfaces for damage or wear and check the oil passages for restriction.

B–02843

4. Use a micrometer to measure the outside diameter of the crank journals and crankpins (Fig. 7B–107). Take measurements at several locations on the crank journals and crankpins to find the amount of wear.

Fig. 7B–107 Checking Crank Journals

5. If the amount of wear is more than0.002” (0,05 mm), have the crank journals and crankpins cut to size indicated in the specifications and install smaller size bearings.

6. Check the crankshaft for axial alignment and correct if the amount measured is above the amount indicated for servicing (Fig. 7B–108).

7. To check the crankshaft for axial alignment, use the following procedure: (a) Put the crankshaft on “V” blocks at each end and hold the point of a dial indicator in contact with the center journal.

B–03000

Fig. 7B–108 Checking Alignment

(b) Slowly turn the crankshaft one full turn and read the dial indicator.

8. Use a feeler gauge to check the crankshaft thrust clearance at the center bearing. If the measured value is over the limit, install an oversize thrust bearing.

NOTE: Install the thrust bearing so that the side toward the crankshaft thrust face.

with the oil groove is

7B–10 CAMSHAFT 7B–10.1 Inspection of the Camshaft 1. Check the journals, cam lobes and oil pump drive gear forwear or damage.

202 of 256

–7B–26–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

2. Have the crank journals ground to installing smaller size bearings.

2. Use a micrometer to measure the height of the cam lobes.

3. Replace the camshaft if the amount of reduction in the height of the cam lobes is over the limit or if the cam surfaces are found to have bad damage.

Small scratches on the cam surfaces can be removed with a polishing stone.

4. Use a micrometer to measure the diameter of the camshaft journals (Fig. 7B–109).

Replace the camshaft if the amount of wear is over the value indicating need for servicing.

B–02996

Fig. 7B–109 Checking Camshaft

B–03001

Fig. 7B–110 Camshaft End Play

Dealer Copy -- Not for Resale

5. Measure the camshaft end play with a feeler gauge (Fig. 7B–1 10). Install a new thrust plate if the measured value is overthe value indicating need for servicing.

7B–11 TIMING GEAR 7B–11.1 Inspection of the Timing Gear

C–02335

1. Check the timing gears for wear of damage. Replace the timing gears if any defect is found.

Fig. 7B–111 Oil Pump Pipe

2. Measure the clearance between the timing gears, using a feeler gauge or dial indicator. Replace the timing gears if the amount of clearance is over the maximum specifications.

7B–12 MANIFOLD ASSEMBLY 7B–12.1 Inspection of the Manifold Assembly 1. Check the intake manifold for cracks, corrosion or damage. Correct or replace the manifold as needed.

2. Check the contact surfaces of the intake and exhaust manifolds for distortion. Replace the part or correct by grinding if the amount of distortion is over the limit for servicing.

7B–13 OIL PUMP AND OIL FILTER ASSEMBLY 7B–13.1 Disassembly of the Oil Pump 1. Disconnect the oil pipe (Fig. 7B–111) from the oil pump.

2. Remove the strainer case and pump cover . Then remove the vane (Fig. 7B–112).

203 of 256

–7B–27–

B–03000

Fig. 7B–112 Oil Pump Assembly 540, 543 Loader Service Manual

3. Remove the pin which holds the pinion.

4. Pull out the pin and remove the rotor.

5. Remove the rotor shaft.

6. Assemble the parts in the reverse of disassembly.

NOTE: When assembling operation is completed, check that the rotor shaft turns smoothly.

B–02986

Fig. 7B–114 Checking Oil Pump

7B–13.2 Inspection of the Oil Pump 1. Make a visual check of the vane, rotor and piston gear for wear. Install new parts if the amount of wear is over the specifications.

C–02337

Fig. 7B–113 Checking Oil Pump

Dealer Copy -- Not for Resale

2. Measure the clearance between the rotor , vane and cover. Make replacement of either the rotor or the vane if the measured amount is over the limit for servicing (Fig. 7B–113).

3. Use a feeler gauge to measure the tip clearance between the rotor and the vane (Fig. 7B–114). Make replacement of the rotor assembly if the measured clearance is over the standard limit.

4. Measure the clearance between the rotor shaft and pump body . Replace the parts if the clearance is over the limit for servicing.

7B–13.3 Oil Filter Assembly (Fig. 7B–115) 1. Remove the oil filter and remove the filter element by turning it counterclockwise.

2. Remove the relief valve and overflow valve.

3. Assemble the parts in the reverse order of disassembly. Install the element by turning it on hand tight only.

C–02343

Fig. 7B–115 Oil Filter Assembly

7B–13.4 Inspection of the Oil Filter Assembly 1. The relief valve and overflow valve can not be disassembled. Make a visual check of these valves for damage or other defect condition and replace the valve if a defect is found.

2. To check the relief valve opening pressure, use the following procedure: Connect a pressure gauge to the oil gallery at a point closest to the oil filter and check the valve opening pressure with the engine running.

7B–14 WATER PUMP (Fig. 7B–116) 7B–14.1 Disassembly of the Water Pump 1. Remove the rear cover from the body and loosen the bearing setscrew (Fig. 7B–117).

204 of 256

B–03010

Fig. 7B–116 Water Pump Assembly –7B–28–

540, 543 Loader Service Manual

2. Remove the sheave center using a puller (Fig. 7B–118).

3. Remove the shaft and impeller from the body using a press (Fig. 7B–119).

NOTE: The impeller is made of cast iron. Do not use a hammer to remove it.

7B–14.2 Inspection of the Water Pump 1. Check the disassembled parts for wear, cracks or other damage and replace the pump if a defect if found.

B–02997

Fig. 7B–117 Bearing Setscrew

2. Check the shaft for being straight.

3. Check the loose bearing unit. Replace the bearing unit if the bearing unit is loose by more than 0.008” (0,2 mm).

1. Install the thrower and the seal unit on the bearing seat location on the shaft.

NOTE: Install the seal unit so that the side with the spring is toward the impeller.

2. Install the shaft in the water pump body from the sheave side. Use a press and align the screw hole in the water pump body with the screw hole for the outer bearing race (Fig. 7B–120).

Dealer Copy -- Not for Resale

7B–14.3 Assembly of the Water Pump

B–02998

Fig. 7B–118 Removing Sheave Center

Press Press

3. Use a press to install the impeller on the shaft. (a) There must be a clearance of about 0.040” (1 mm) between the rear face of the impeller and the inner face of the pump body.

A–02528

Fig. 7B–119 Removing Shaft and Impeller

B–02999

Fig. 7B–120 Installing Impeller Shaft

(b) Standard clearance between the outer circumference of the impeller and the pump body is 0.047–0.051” (1,2–1,3 mm) (Fig. 7B–121).

4. Use a press to install the sheave center (Fig. 7B–122).

Press

5. Tighten the setscrew and install the rear cover.

NOTE: When assembly operation is completed, check that the impeller turns smoothly.

205 of 256

A–02523

A–02529

Fig. 7B–121 Checking Impeller Clearance

Fig. 7B–122 Installing Sheave Center

–7B–29–

540, 543 Loader Service Manual

7B–15 ASSEMBLY OF THE ENGINE 7B–15.1 Assembly of the Engine 1. Wash and clean the disassembled parts, such as the oil ports, bearings, pistons, cylinders, etc.

2. Put engine oil on the cylinder walls and the bearings and pistons.

3. Install new gaskets at the time of assembly. Use a liquid gasket where it is necessary to prevent oil leakage.

B–02834

4. Check the oil clearance and other clearances when assembling the parts.

Fig. 7B–123 Installing Crankshaft Bearings

5. Tighten the bolts and nuts to the correct torque.

6. Install the upper half of the crankshaft bearings and thrust bearings on the cylinder block (Fig. 7B–123).

Dealer Copy -- Not for Resale

NOTE: Install the thrust bearing so that the side with the oil groove is away from the crankshaft bearings.

7. Put a thin layer of sealant on the connecting areas of the No. 1 and No. 3 bearing caps. Install the bearing caps.

8. Install and tighten the bolts in the bearing caps to the correct torque.

9. When the crankshaft is correctly installed, check the crankshaft for the correct end clearance.

10. Install the gasket on the No. 1 and No. 3 bearing caps. Put sealant on the inner surface of the gasket and install the gasket evenly into the grooves in the bearing cap (Fig. 7B–124). Hold it with the finders for about 5 minutes.

Make sure the gasket is 0.002” (0,05 mm) above theend of the bearing cap.

11. Put a thin layer of silicone rubber–base sealant on the outer circumference of the rear oil seal.

Cylinder Body Oil Seal Crankshaft

12. Fill the clearance between the lips of the oil seal with grease.

Install the oil seal.

13. Install the rear plate.

Setting Tool

Hammer

Grease

14. Install the flywheel (See Paragraph 7B– . ).

15. Set the piston ring gaps so that their gaps are 180 ° apart from each other.

206 of 256

Adhesive

PI–02097

Fig. 7B–124 Installing Gasket on Bearing Cap –7B–30–

540, 543 Loader Service Manual

NOTE: Put engine oil on the cylinder walls and around the pistons and the piston rings.

16. Use a piston ring compressor tool to install the piston and connecting rod assembly. The front mark on top of the piston must be toward the water pump end of the engine and the connecting rodmust be installed so that the mark is toward the camshaft side.

17. Install and tighten the connecting rod bearing cap bolts. Then check connecting rod end clearance.

the C–02335

Fig. 7B–125 Installing Oil Pump NOTE: Before installing, put cement on the surface of the engine front plate in contact with the cylinder body and injection pump and put the gasket in place.

18. Install the tappets into position from the oil pan side.

20. Install the oil pump assembly and connect the oil pipe (Fig. 7B–125).

Dealer Copy -- Not for Resale

19. Install the camshaft. Then install the thrust plate on the cylinder block.

B–02833

Fig. 7B–126 Installing Timing Gears

21. Install the oil pan on the crankcase and fasten the crankcase to the cylinder block.

Use the following procedure: (a) Put cement on the upper and lower surfaces of the crankcase, both sides of the oil pan gasket and No. 1 and No.3 bearing cap gaskets for the crankshaft.

”Y” Marks

(b) Let the cement dry for 10–30 minutes. (c) Tighten the 4 bolts around the bearing caps. T ighten the remainder of the bolts evenly in sequence.

Then finish tightening the 4 bolts.

22. Install the timing gears (Fig. 7B–126).

”Z” Marks

NOTE: Install the idler gear thrust collar on the idler shaft and install the timing gears so that the “X” and “Y” marks are in correct alignment (Fig. 7B–127).

”X” Marks A–02508

Fig. 7B–127 Timing Gear Alignment 207 of 256

–7B–31–

540, 543 Loader Service Manual

23. Install the cylinder head.

24. First tighten the cylinder head bolts to 20–35 ft.–lbs. (25–45 Nm) torque in sequence starting with those in the center of the cylinder head (Fig. 7B–128).

Then tighten them further to a torque of 45 ft.–lbs. (60 Nm). Then tighten them to the last torque of 60 ft.–lbs. (80 Nm).

25. Connect the oil tubeline for the rocker shaft.

26. Install the push rods.

27. Install the rocker shaft assembly.

28. Adjust the valves for the correct clearance. The clearance is set cold. Use the following procedure to set the valves: (a) Turn the engine and stop it when the exhaust valve on the No. 2 cylinder is ready to open.

B–02984

Fig. 7B–128 Cylinder Head Torque Sequence

(c) Hold the engine stationary and adjust the intake and exhaust valve clearance on the No. 1 cylinder.

7

5

9

10

11

(d) Adjust the intake valve on the No. 2 cylinder. (e) Turn the crankshaft one complete revolution so that the piston of the No. 2 cylinder is at the bottom of the intake stroke. (f) Hold the engine and adjust the exhaust valve clearance on the No. 2 cylinder.

29. Install the crankshaft front oil seal on the timing gear cover and fasten the cover with the bolts.

NOTE: Fill the space between the lips of the oil seal with grease before installing the oil seal.

3

4

1

2

8

6

B–02913

Fig. 7B–129 Timing Marks

30. Install the injection pump and fasten it with the long bolts forthe timing gear cover (Fig. 7B–129).

NOTE: Align the mark “Z” on the injection pump gear with the mark “Z” on the camshaft gear (See Paragraph 7B–2.6).

31. Install the crankshaft sheave on the crankshaft and tighten the bolt. Bend part of the washer over the head of the bolt.

NOTE: Put a thin layer of oil on the counterbore of the oil sheave, before installing the sheave.

seal on the

Nozzle assy Nozzle washer Corrugate washer Heat shield Hot plug

32. Install the injection nozzle (See Paragraph 7B–2.8) (Fig. 7B–130).

33. Install the rocker arm cover.

PI–02082

Fig. 7B–130 Installing Injection Nozzle 208 of 256

–7B–32–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

(b) Align the top mark on the crank sheave with the pointer on the timing gear cover (Piston on the No. 1 cylinder is now TDC).

34. Install the manifold gasket and muffler/manifold. Install the lifting hook at the rear of the engine.

35. Install the thermostat and thermostat housing. Fasten the thermostat housing and lifting hook with the bolts and tighten.

36. Install the water pump assembly.

B–05242

Fig. 7B–131 Flywheel Housing 37. Install the alternator fastening bracket and the coolant temp– erature switch. Install the alternator and the bolts (See Paragraph 6–7.1, Page 6–6 for the correct belt tension).

B–05323

38. Install the o–ring on the oil filter and fasten the oil filter assembly to the cylinder block.

Fig. 7B–132 RemovingFlywheel Housing

Dealer Copy -- Not for Resale

39. Install the starter (See Paragraph 6–9.4, Page 6–15).

40. Install the engine in the loader (See Paragraph 7B–3.3).

41. Make sure to add coolant to the radiator and oil to the crankcase before you start the engine.

7B–16 ENGINE FLYWHEEL 7B–16.1 Removing the Flywheel 1. Remove the bolts from the flywheel housing (Fig. 7B–131).

2. Use a pry bar and pry the flywheel housing away from the engine (Fig. 7B–132). Remove the flywheel housing.

3. Remove the adapter bolt (Fig. 7B–133).

4. Use a puller and remove the adapter (Fig. 7B–134).

B–05317

Fig. 7B–133 Adapter Bolt 5. Remove the bolts from the flywheel (Fig. 7B–135).

6. Remove the flywheel from the engine crankshaft.

7B–16.2 Installing the Flywheel 1. Install the flywheel on crankshaft.

the

2. Install the bolts in the flywheel and tighten to 58 ft.–lbs. (79 Nm) torque (Fig. 7B–135).

209 of 256

B–05289

Fig. 7B–134 Removing the Adapter –7B–33–

B–05315

Fig. 7B–135 Flywheel Bolts 540, 543 Loader Service Manual

3. Install the key and the adapter on the flywheel (Fig. 7B–136).

4. Install the adapter bolt and tighten to 20–25 ft.–lbs. (27–34 Nm) torque.

B–05316

Fig. 7B–136 Installing Adapter

Dealer Copy -- Not for Resale

5. Install the flywheel housing, the bolts and tighten.

210 of 256

–7B–34–

540, 543 Loader Service Manual

TECHNICAL DATA

DECIMAL AND MILLIMETER EQUIVALENTS . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS–540 LOADER (KOHLER) . . . . . . .

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston, Pin & Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves, Guides & Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS–543 LOADER (ISUZU) . . . . . . . . .

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pump & Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS . . . . .

LOADER SPECIFICATIONS–540 . . . . . . . . . . . . . . . . . . . . . . . . .

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOADER SPECIFICATIONS–543 . . . . . . . . . . . . . . . . . . . . . . . . .

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STANDARD TORQUE SPECIFICATIONS FOR BOLTS . . . . . .

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake, Axle & Chaincase Group . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Group – 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Group – 543 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Group – 543 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic Group – 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic Group – 543 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Guard, Lift Arms & Main Frame Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Bar, Fuel Tank & Panel Group . . . . . . . . . . . . . . . . . . . . . .

Steering Levers, Linkage & Pedal Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . .

211 of 256

–8––1–

Page Number

8–7 8–3 8–3.4 8–3.3 8–3.2 8–3.1 8–3.8 8–3.6 8–3.7 8–4 8–4.7 8–4.5 8–4.6 8–4.1 8–4.16 8–4.15 8–4.14 8–4.12 8–4.3 8–4.4 8–4.11 8–4.8 8–4.9 8–4.10 8–4.13 8–6 8–1 8–1.6 8–1.5 8–1.4 8–1.2 8–1.3 8–1.1 8–1.7 8–2 8–2.6 8–2.5 8–2.4 8–2.2 8–2.3 8–2.1 8–2.7 8–9 8–5 8–5.6 8–5.1 8–5.2 8–5.3 8–5.10 8–5.8 8–5.9

8–21 8–5 8–5 8–5 8–5 8–5 8–6 8–5 8–5 8–7 8–7 8–7 8–7 8–7 8–9 8–8 8–8 8–8 8–7 8–7 8–8 8–7 8–8 8–8 8–8 8–20 8–1 8–2 8–2 8–2 8–1 8–2 8–1 8–2 8–3 8–4 8–4 8–4 8–3 8–4 8–3 8–4 8–22 8–10 8–15 8–10 8–11 8–12 8–19 8–17 8–18

8–5.7 8–5.4

8–16 8–13

8–5.5 8–8

8–14 8–21

Dealer Copy -- Not for Resale

Paragraph Number

TECHNICAL DATA

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 212 of 256

–8–0–

540, 543 Loader Service Manual

8–1 540 LOADER SPECIFICATIONS 97°

127.5 (3239)

62.5 (1588)

102.5 (2604)

36° 18 (457) 72.5 (1842)

49.5 (1257)

42 (1067)

85 (2159)

32 (813) 27°

51 (1308) 24°

7.2 (183)

31 (787)

6.5 (165)

82 (2083)

30 (775)

38 (965) 47.2 (1199)

104 (2642)

Dealer Copy -- Not for Resale

PI–02586

Where applicable specifications conform to SAE standard and are subject to change without notice.

Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

8–1.1 Specifications

Weight Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3250 lbs. (1474 kg) Rated Operating Capacity (Melroe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 . . . .lbs. (363 kg) Tipping Load (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1600 lbs. (726 kg) Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0. to 5.5 MPH (8,9 Km/hr.)

Controls Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction ..... and speed control by two levers Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift, . . . .tilt functions controlled by separate foot pedals.

Auxiliary function controlled by the right steering lever.

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hand . . . . lever throttle & key type starter switch.

Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic .

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical ..... disc, foot operated pedal.

8–1.2 Engine

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kohler .

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K582S ..

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gasoline .

Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19.2 HP (14,3 kW) Maximum Governed RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2500 RPM Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 . ft.–lbs. (56 Nm) @ 2200 RPM Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50 (88,9)/3.00 (72,2) Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.7 cu.in. (945,5 cm#) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air ..

Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dry . . . replaceable paper element Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 . . volt, . . battery ignition W/breaker, points & coil.

High Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2675–2725 Low Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .900–1100

213 of 256

–8–1–

540, 543 Loader Service Manual

8–1.3 Loader Hydraulics Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine driven, vane type Pump Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3 . . .gpm . (31 L/min.) @ 2500 RPM System Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1675 . . . . PSI .

(11549 kPa) Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . .Micron replaceable cartridge in the return line from the cooler.

Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doubleacting Bore Diameter Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.0 (50,8) Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.0 (76,2) Rod Diameter Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 .

(31,8)r Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.50 (38,1) Stroke Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.2 (563,9) Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 .

(315) Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–spool, .... open center type W/float detent on the lift and detent on the auxiliary.

Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SAE . . . . standard full flow tubes, hoses & fittings.

8–1.4 Electrical Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 . . .amp. flywheel @ 3600 RPM Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 . . volt, 370 cold crank amps @ 0°F. (–17,8°C.) 106 min. reserve capacity.

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 volt, gear drive

8–1.5 Drive System Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic .... infinitely variable, fully reversing.

Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chains ... & sprockets in sealed crankcase with oil lubrication.

Total Engine to Wheel Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.3:1 .

8–1.6 Capacities Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . gal. (49 L) Engine Lubrication W/filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . qts. (3,8 L) Hydraulic/Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. .gal. . (23 L) (Includes 3.5 gal. (12,4 L) in the reservoir).

Chaincase Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 gal. (15 L)

8–1.7 Tires Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.70 X 15,4 ply rating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45–50 PSI (310–345 kPa) Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 X 8.50, 4 ply rating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . PSI (172 kPa)

214 of 256

–8–2–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

Hydraulic Function Time: Raise Lift Arms to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 . . . Seconds ..

Lower Lift Arms from Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.0 . . .Seconds .

Move Bucket to Dump Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 . . . Seconds ..

Move Bucket to Retracted Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 . . . Seconds ..

8–2 LOADER SPECIFICATIONS 97°

127.5 (3239)

62.5 (1588)

102.5 (2604)

36° 18 (457) 72.5 (1842)

49.5 (1257)

42 (1067)

85 (2159)

32 (813) 27°

51 (1308) 24°

7.2 (183)

31 (787)

6.5 (165)

82 (2083)

30 (775)

38 (965) 47.2 (1199)

104 (2642)

Dealer Copy -- Not for Resale

PI–02586

Where applicable specifications conform to SAE standard and are subject to change without notice.

Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

8–2.1 Specifications

Weight Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3360 lbs. (1524 kg) Rated Operating Capacity (Melroe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 . . . .lbs. (363 kg) Tipping Load (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1600 lbs. (726 kg) Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0–5.5 MPH (8,9 Km/hr.)

Controls Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction .... and speed control by two hand levers.

Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift, . . . .tilt functions controlled by separate foot pedals.

Auxiliary function controlled by the right steering lever.

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hand . . . . lever throttle & key type starter switch.

Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic .

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical ..... disc, foot operated pedal.

8–2.2 Engine

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Isuzu .

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2AA1 ..

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diesel ..

Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 HP (14 kW) Maximum Governed RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2500 RPM Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 . ft.–lbs. (53 Nm) @ 2000 RPM Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39 .

(86)/3.31 (84) Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 cu.in. (983,2 cm#) Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Liquid .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure System W/Filter Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .External Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dry . . . replaceable paper element High Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2650–2750 Low Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .750–800

215 of 256

–8–3–

540, 543 Loader Service Manual

8–2.3 Loader Hydraulics Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine driven, vane type Pump Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3 . . .gpm . (31 L/min.) @ 2500 RPM System Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1675 . . . . PSI (10860 kPa) Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . .Micron replaceable cartridge in the return line from the cooler.

Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doubleacting Bore Diameter Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.0 (50,8) Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.0 (76,2) Rod Diameter Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25 (31,8) Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.50 (38,1) Stroke Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22.2 (563,9) Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 .

(315) Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. spool, .. open center type W/float detent on the lift Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SAE . . . . standard full flow tubes, hoses & fittings.

8–2.4 Electrical Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt driven, 37 amp.

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 . . volt, 370 cold crank amps @ 0°F. (–17,8°C.) 106 min. reserve capacity.

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 volt, gear drive

8–2.5 Drive System Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic .... infinitely variable, fully reversing.

Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chains ... & sprockets in sealed crankcase with oil lubrication.

Total Engine to Wheel Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.3:1 .

8–2.6 Capacities Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . qts. (8,4 L) Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . gal. (49 L) Engine Lubrication W/filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . qts. (3,8 L) Hydraulic/Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. .gal. . (23 L) (Includes 3.5 gal. (12,4 L) in the reservoir).

Chaincase Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 gal. (15 L)

8–2.7 Tires Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.70 . x 15,4 ply rating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45–50 PSI (310–345 kPa) Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 x 8.50, 4 ply rating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . PSI (172 kPa)

216 of 256

–8–4–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

Hydraulic Function Time: Raise Lift Arms to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 . . . Seconds ..

Lower Lift Arms from Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.0 . . .Seconds .

Move Bucket to Dump Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 . . . Seconds ..

Move Bucket to Retracted Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 . . . Seconds ..

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parenthesis.

8–3 ENGINE SPECIFICATIONS – 540 LOADER (KOHLER) 8–3.1 Engine (General) Ignition Point Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.018–0.022 ....

(0,46–0,56) Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.035 (0,9) Compression at Cranking Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100–120 ....

PSI (690–827 kPa) High Idle at No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2700 RPM Low Idle at No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 RPM Oil Pressure (Idle RPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40–50 . . . . PSI (276–345 kPa) 8–3.2 Cylinder Bore New Diameter 3.50 (88,9) Wear Diameter (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.503 ..

(88,98) Taper (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0015 (0,038) Out–of–Round (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.005 .

(0,127) 8–3.3 Crankshaft

Dealer Copy -- Not for Resale

End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004–0.010 (0,10–0,25) Crankpin–New Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.625 (41,28) Crankpin–Out–of–Round (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0005 . . . . (0,013) Crankpin–Taper (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.001 ..

(0,025) Crankshaft Sleeve Bearing–Running Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0015–0.005 ..

(0,038–0,127) Crank Journal Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.750 (44,5) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.003 (0,08) 8–3.4 Camshaft

End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.017–0.038 (0,43–0,97) Shaft to Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0005–0.0035 ....

0,013–0,089 8–3.5 Connecting Rod

Big End–Wear Diameter (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.627 . . . . (41,33) Rod to Crankpin–Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0035 . . . . (0,089) Small End–New Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.875 (22,23 Rod to Piston Pin–Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0003–0.0008 ....

(0,008–0,020) Side Play on Crankpin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.005–0.014 ....

(0,127–0,36) 8–3.6 Piston, Pin & Rings *Thrust Face–Wear Diameter (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.495 . . . . (88,77) *Thrust Face to Bore–Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.007–0.010 ...

(0,178–0,25) Ring–Side Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 . . . . . (0,15) Ring–End Gap in Used Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 ..

(0,76) Pin to Boss Clearance (Loose) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0005 . . . . . (0,0127) Pin to Rod Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0003–0.0008 ....

(0,008–0,020) 8–3.7 Valves, Guides & Tappets

Intake Valve to Tappet Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.008–0.010 ...

(0,20–0,25) Exhaust Valve to Tappet Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.017–0.020 ...

(0,43–0,51) Valve Lift–Zero Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.324 (8,23) Intake Valve Stem to Guide Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0045 ...

(0,114) Exhaust Valve Stem to Guide Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0065 ...

(0,165) Tappet Clearance in Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0012–0.0023 ....

(0,03–0,06) Guide Interference Fit in Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005–0.002 ....

(0,0127–0,051) Guide Ream Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.312–0.313 ....

(7,93–7,95) Valve Seat Angle (Degrees) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45° Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 (0,76) *Measured Just Below the Oil Ring at Right Angles to Pin.

217 of 256 Revised Nov. 89

–8–5–

540, 543 Loader Service Manual

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parenthesis.

8–3 ENGINE SPECIFICATIONS – 540 LOADER (KOHLER) (Cont’d) 8–3.8 Engine Torque

Flywheel Retainer Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 . . .ft.–lbs. .

(156 Nm) Camshaft Retainer Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 . . .ft.–lbs. (54 Nm) Oil Pan Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 ft.–lbs. (41 Nm) Manifold Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 ft.–lbs. (34 Nm) Closure Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ft.–lbs. (41 Nm) *Connecting Rod Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . .ft.–lbs. (27 Nm) Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . ft.–lbs. (27 Nm) *Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 . ft.–lbs. (48 Nm)

Dealer Copy -- Not for Resale

*Lightly Oiled Threads

218 of 256

–8–6–

540, 543 Loader Service Manual

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parenthesis.

8–4 ENGINE SPECIFICATIONS –543 LOADER (ISUZU) Engine compression at 250 RPM at 167°F. (75°C.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .398 . . . PSI (2744 kPa) 8–4.1 Cylinder Block Wear of the Cylinder Bore At the Depth from the Top Surface 0.51 (13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Above . . . 0.016 (0,4) Top Surface Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Below . . . 0.002 (0,05) 8–4.2 Cylinder Head Valve Seat Angle 45° Valve Seat Width 0.047–0.06 (1,2–1,5) Cylinder Head Surface Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Below . . . . 0.002 (0,05) Cylinder Head Manifold Surface Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Below . . . . 0.002(0,05) Valve Seat Depth (Normal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 (3,0) (Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 (3,6) 8–4.3 Piston Clearance Between Piston & Cylinder Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003–0.004 ...

(0,08–0,10) Interference Fit the Piston Pin into Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00015 ....

(0,004) Wear of the Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.063 .

(27)

Dealer Copy -- Not for Resale

8–4.4 Piston Ring

Piston Ring Gap (In a 3.3858 [86] Bore) Compression Ring 1st, 2nd, 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008–0.0016 ....

(0,2–0,4) Oil Control Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004–0.012 .

(0,1–0,3) Clearance Between Ring Groove & Ring Compression 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002–0.003 ....

(0,05–0,08) Compression 2nd, 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0012–0.0023 ....

(0.03–0,06) Oil Control Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008–0.002 ....

(0,02–0,05) 8–4.5 Connecting Rod

Clearance Between Rod Bearing & Crankpin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016 . . . . (0,04) Clearance Between Piston Pin & Small End Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0003–0.001 ..

(0,008–0,025) Play in the Axial Direction of Rod & Crankpin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.007–0.012 ...

(0,18–0,30) Twist of the Holes of Big End & Small End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Below . . . 0.003 (0,08) Parallelism of the Holes of Big End & Small End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Below . . . 0.002 (0,05) 8–4.6 Crankshaft Main Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.756 (70,0) Rod Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.08 (53,0) Wear of Main Bearing Journal (Max.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7165 . . . . (69,0) Wear of Rod Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.047 . . . (52,0) Clearance Between Journal & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.001–0.0033 ...

(0,025–0,084) Play of the Crankshaft in the Axial Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 . . . . (0,10) Deflection of the Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Below . . . . 0.0012 (0,03) 8–4.7 Camshaft Deflected Wear of Camshaft Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Below . . . . 0.0012 (0,03) Clearance Between Camshaft & Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 . . . . (0,05) Wear of the Camshaft Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.874 . . . (47,6) Height of the Cam Lobe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32 (33,5) . . . . (0,08) Play of the Camshaft in the Axial Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 8–4.8 Timing Gear Back Lash of the Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Below . . . . 0.004 (0,10) Interference Between Crankgear & Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Below . . . 0.001 (0,025) Interference Between Camgear & Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Below . . . 0.0008 (0,020) Clearance Between Idle Gear Bush & Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.002 . . . . (0,05) Deflected Wear of Idle Gear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Above . . . . 0.004 (0,1) Play of the Idler Gear in the Axial Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0028 . . . . (0,07) 219 of 256

Revised Nov. 89

–8–7–

540, 543 Loader Service Manual

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parenthesis.

8–4 ENGINE SPECIFICATIONS – 543 LOADER (ISUZU) (Cont’d) 8–4.9 Valve Intake Valve Stem Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.310 (7,88) Exhaust Valve Stem Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.309 (7,85) Clearance Between Intake Valve Stem & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.002 . . . (0,05) Clearance Between Exhaust Valve Stem & Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0031 ...

(0,08) Interference Between Valve Guide & Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0008 ...

(0,02) Valve Head Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051 (1,3) Height of Valve Guide in Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake, . . . . 0.512 (13) Exhaust, 0.551 (14) Lip of Valve Guide Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.295 (7,5) Intake & Exhaust Valve Clearance (Cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.017 . . . . (0,43) Clearance Between Rocker Shaft & Bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016 . . . . (0,04) Rocker Arm Shaft Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.742 (18,85) Bending of Push Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Above .

0.012 (0,3)

Valve Spring (Outer) Free Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.81 .

(46) Force at 1.54 (39) Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.8 . . . . lbs. . (18,5 kg) Valve Spring (Inner) Free Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.69 (42,9) Force at 1.46 (37) Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3 . . . . lbs. . (8,3 kg) 8–4.11 Tappet Clearance Between Tappet & Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0011 . . . (0,03) Wear of Tappet (O.D.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.510 (12,95) 8–4.12 Oil Pump and Relief Valve Oil Pressure @ 1400 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57–64 . . . . PSI (393–441 kPa) Clearance: Between Rotor and Vane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Below . . . . 0.006 (0,15) Between Pump Cover and Rotor or Vane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008–0.0028 ...

(0,02–0,07) Between Vane and Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.008–0.011 ....

(0,2–0,28) Between Pump and Shaft & Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016 . . . . (0,04) Relief Valve Actuating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 . . .PSI . . (441 kPa) 8–4.13 Water Pump Wear in the Water Pump Ball Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.008 . . . . (0,2) Clearance Between Pump Impeller & Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.012–0.024 ..

(0,3–0,6) Thermostat Opening Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Beginning, ...

166–173°F. (74,5–78,5°C.) Full, 194°F. (90°C.) 8–4.14 Fuel Lift Pump Pumping Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suction ... must start within 30 times of manual operation.

Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3 cu. in. (300 cc) 8–4.15 Fuel Injector Fuel Tightness of the Needle Valve Shaft Time it takes for the pressure to drop from 3556 to 2845 PSI (24518 to 19616 kPa) while the initial pressure applied is 4267 PSI (29420 kPa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Above . . . . 6 Seconds Nozzle Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1707 . . . . .PSI (11769 kPa)

220 of 256

Revised Nov. 89

–8–8–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

8–4.10 Valve Spring

All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parenthesis.

8–4 ENGINE SPECIFICATIONS – 543 LOADER (ISUZU) (Cont’d) 8–4.16 Engine Torque

Dealer Copy -- Not for Resale

Main Bearing Cap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 . . . ft.–lbs. .

(163 Nm) Flywheel to Crankshaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 . . ft.–lbs. ...

(79 Nm) Connecting Rod Cap Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 . . ft.–lbs. ...

(79 Nm) Camshaft Thrust Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 . . ft.–lbs. ...

(68 Nm) Crankshaft to Block Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 . . ft.–lbs. ..

(20 Nm) Oil Pan Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 ft.–lbs. (8 Nm) Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 . ft.–lbs. (80 Nm) Rocker Arms Assembly Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 . . .ft.–lbs. ..

(27 Nm) Crankshaft Sheave Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 . . . ft.–lbs. .

(146 Nm) Injectors Nozzle Holding Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 . . .ft.–lbs. ..

(73 Nm)

221 of 256

–8–9–

540, 543 Loader Service Manual

8–5 TORQUE SPECIFICATIONS 8–5.1 Engine Group – 540 Loader

Torque

1.

30–40 in.–lbs.

(4–5 Nm)

2.

15–17 ft.–lbs.

(21–23 Nm)

3.

80–90 in.–lbs.

(9–10 Nm)

4.

16–20 ft.–lbs.

(22–27 Nm)

5.

Adjust to give the throttle lever a tension of 3–13 ft.–lbs. (4–8 Nm) torque.

6.

25–28 ft.–lbs.

(34–38 Nm)

7.

65–70 ft.–lbs.

(88–95 Nm)

6

5

2

4

Dealer Copy -- Not for Resale

Ref.

7

2

1

3 C–02008R D–01293R E–01370

222 of 256

–8–10–

540, 543 Loader Service Manual

8–5 TORQUE SPECIFICATIONS (Cont’d) 8–5.2 Engine Group – 543 Loader Torque

1.

18–19 ft.–lbs.

(24–26 Nm)

2.

25–28 ft.–lbs.

(34–38 Nm)

3.

16–20 ft.–lbs.

(22–27 Nm)

4.

15–17 ft.–lbs.

(21–23 Nm)

3

1

4

2

Dealer Copy -- Not for Resale

Ref.

1

2

223 of 256

–8–11–

540, 543 Loader Service Manual

8–5 TORQUE SPECIFICATIONS (Cont’d) 8–5.3 Engine Group – 543 Loader

2 Ref.

Torque

1.

40–60 ft.–lbs.

(54–81 Nm)

2.

25–28 ft.–lbs.

(54–81 Nm)

3.

65–70 ft.–lbs.

(88–95 Nm)

4.

20–25 ft.–lbs.

(27–34 Nm)

5.*

55–70 ft.–lbs.

(75–95 Nm)

6.

90–100 ft.–lbs.

(125–140 Nm)

7.

Adjust to give the throttle lever a tension of 3–13 ft.–lbs. (4–8 Nm) torque.

25–40 in.–lbs.

(3–5 Nm)

9.

35–40 in.–lbs.

(4–5 Nm)

10.

15–17 ft.–lbs.

(21–23 Nm)

10

Dealer Copy -- Not for Resale

8.

2

9

1

4

2

1 5

6

224 of 256

3

D–01379R C–02221 E–01373

–8–12–

540, 543 Loader Service Manual

8–5 TORQUE SPECIFICATIONS (Cont’d) 8–5.4 Seat Bar, Fuel Tank & Panel Group Ref.

Torque

1.

25–29 ft.–lbs.

(34–38 Nm)

2.

16–20 ft.–lbs.

(22–27 Nm)

3.

40–45 ft.–lbs.

(54–61 Nm)

4.

9–11 ft.–lbs.

(12–15 Nm)

3

4 3 2

2 1 1 2 543 Loader

540 Loader

Dealer Copy -- Not for Resale

1

2

2

D–01548 C–02607 E–01324 E–01343

225 of 256

–8–13–

540, 543 Loader Service Manual

8–5 TORQUE SPECIFICATIONS (Cont’d) 8–5.5 Steering Levers, Linkage & Pedal Group Torque

1.

25–28 ft.–lbs.

(34–38 Nm)

2.

18–20 ft.–lbs.

(24–27 Nm)

3.

11–13 ft.–lbs.

(15–18 Nm)

4.

21–25 ft.–lbs.

(28–34 Nm)

1

1 1

1

1

Dealer Copy -- Not for Resale

Ref.

1

3

3 1 1 4

4

1

3 4

1

1

2

1

1 1 2

3 1

D–01431R D–01510

226 of 256

–8–14–

540, 543 Loader Service Manual

8–5 TORQUE SPECIFICATIONS (Cont’d) Torque

1.

260–300 ft.–lbs.

(353–407Nm)

2.

16–20 ft.–lbs.

(22–27 Nm)

3.

65–70 ft.–lbs.

(88–95 Nm)

4.*

65–70 ft.–lbs.

(88–95 Nm)

5.*

300–330 ft.–lbs.

(407–447 Nm)

6.

25–28 ft.–lbs.

(34–38 Nm)

7.

110–120 ft.–lbs.

(149–163 Nm)

8.

55–65 ft.–lbs.

(75–88 Nm)

3

3 2 4

Dealer Copy -- Not for Resale

Ref.

1

7

5

8 * Put Lock–Tite on the Threads

D–01565 D–01371R C–02659

Revised Nov. 89 227 of 256

–8–15–

540, 543 Loader Service Manual

8–5 TORQUE SPECIFICATIONS (Cont’d) 8–5.7 Mainframe Group Ref.

Torque

1.

55–65 ft.–lbs.

(75–88Nm)

2.

90–100 ft.–lbs.

(122–136 Nm)

3.

20–40 ft.–lbs.

(27–54 Nm) Required to push the handle into lock position.

4.

40–50 ft.–lbs.

(54–68 Nm)

5.

65–70 ft.–lbs.

(88–95 Nm)

4

10 5 5

80–90 ft.–lbs.

(9–10 Nm)

7.

15–17 ft.–lbs.

(20–23 Nm)

8.

16–20 ft.–lbs.

(22–27 Nm)

9.

125–140 ft.–lbs.

(170–190 Nm)

10.

23–25 ft.–lbs.

(31–34 Nm)

4 10

6

4

3

2

7

1

8

8 8

9

E–01374 C–02658 D–01280 E–01321

Revised Nov. 89 228 of 256

–8–16–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

6.

5

8–5 TORQUE SPECIFICATIONS (Cont’d) 8–5.8 Hydrostatic Group – 540 Loader Ref.

Torque

1.

16–20 ft.–lbs.

(22–27 Nm)

2.

25–28 ft.–lbs.

(34–38 Nm)

3.

65–70 ft.–lbs.

(88–95 Nm)

4.

90–100 ft.–lbs.

(125–135Nm)

3

2

1

Dealer Copy -- Not for Resale

1

4

3 E–01369 D–01516R C–02009 229 of 256

–8–17–

540, 543 Loader Service Manual

8–5 TORQUE SPECIFICATIONS (Cont’d) 8–5.9 Hydrostatic Group – 543 Loader Torque

1.

16–20 ft.–lbs.

(22–27 Nm)

2.

160–180ft.–lbs.

(217–244 Nm)

3.

65–70 ft.–lbs.

(88–95 Nm)

4.

25–28 ft.–lbs.

(34–38Nm)

5.

90–100 ft.–lbs.

(125–135 Nm)

3

4 1

1

Dealer Copy -- Not for Resale

Ref.

4

5

3

2

3

D–01515 E–01371 C–02009 230 of 256

–8–18–

540, 543 Loader Service Manual

8–5 TORQUE SPECIFICATIONS (Cont’d) 8–5.10 Hydraulic Group Ref.

Torque

1.

11–13 ft.–lbs.

(15–18 Nm)

2.

31–33 ft.–lbs.

(42–45 Nm)

3.

16–20 ft.–lbs.

(22–27 Nm)

3 1

Dealer Copy -- Not for Resale

1

2

D–01284 D–01457R 231 of 256

–8–19–

540, 543 Loader Service Manual

8–6 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS

8–6.1 Hydraulic/Hydrostatic Fluid

Use Clark hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not available, use 10W–30 or 10W–40 SAE Motor Oil.

Where temperatures below zero are common, loaders must be kept in a warm building. Extra warm–up time must be used each time the loader is started during cold temperature conditions. Cold fluid will not flow easily and makes action of the hydraulic function slower. Loss of fluid flow to the hydrostatic transmission pump (indicated by “TRANS” light “ON”) will cause transmission damage in less than 60 seconds time.

IMPORTANT

232 of 256

Stop the engine if the “TRANS” light comes “ON” and stays “ON”. The light indicates the loss of fluid flow to the hydrostatic pumps which will cause transmission damage in less than 60 seconds time.

–8–20–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

DO NOT USE automatic transmission fluids in this loader or permanent damage to the transmission will result.

8–7 DECIMAL AND MILLIMETER EQUIVALENTS 1/64

1/32

3/64

1/16

5/64

3/32

7/64

1/8

9/64

5/32

11/64

3/16

13/64

7/32

15/64

1/4

17/64

9/32

19/64

5/16

21/64

11/32

23/64

3/8

25/64

13/32

27/64

7/16

29/64

15/32

31/64

1/2

DECIMALS

MM

0.015625 — 0.03125 — 0.046875 — 0.0625 — 0.078125 — 0.09375 — 0.109375 — 0.1250 — 0.140625 — 0.15625 — 0.171875 — 0.1876 — 0.203125 — 0.21875 — 0.234375 — 0.2500 — 0.265625 — 0.28125 — 0.296875 — 0.3125 — 0.328125 — 0.34375 — 0.359375 — 0.3750 — 0.390625 — 0.40625 — 0.421875 — 0.4375 — 0.453125 — 0.46875 — 0.484375 — 0.5000 —

0.397 0.794 1.191 1.588 1.984 2.381 2.778 3.175 3.572 3.969 4.366 4.762 5.159 5.556 5.953 6.350 6.747 7.144 7.541 7.938 8.334 8.731 9.128 9.525 9.922 10.319 10.716 11.112 11.509 11.906 12.303 12.700

FRACTIONS 17/32 9/16 19/32 5/8 21/32 11/16 23/32 3/4 25/32 13/16 27/32 7/8 29/32 15/16 31/32 1

1 mm = 0.03937’’

33/64 35/64 37/64 39/64 41/64 43/64 45/64 47/64 49/64 51/64 53/64 55/64 57/64 59/64 61/64 63/64

MM

0.515625 — 0.53125 — 0.546875 — 0.5625 — 0.578125 — 0.59375 — 0.609375 — 0.6250 — 0.640625 — 0.65625 — 0.671875 — 0.6875 — 0.703125 — 0.71875 — 0.734375 — 0.7500 — 0.765625 — 0.78125 — 0.796875 — 0.8125 — 0.828125 — 0.84375 — 0.859375 — 0.8750 — 0.890625 — 0.90625 — 0.921875 — 0.9375 — 0.953125 — 0.96875 — 0.984375 — 1.000 —

13.097 13.494 13.891 14.288 14.684 15.081 15.478 15.875 16.272 16.669 17.066 17.462 17.859 18.256 18.653 19.050 19.447 19.844 20.241 20.638 21.034 21.431 21.828 22.225 22.622 23.019 23.416 23.812 24.209 24.606 25.003 25.400

0.001’’ = 0.0254 mm

8–8 U.S. TO METRIC CONVERSION TO CONVERT

INTO

LINEAR MEASUREMENT

Miles Yards Feet Feet Inches Inches Inches

Kilometers Meters Meters Centimeters Meters Centimeters Millimeters

1.609 0.9144 0.3048 30.48 0.0254 2.54 25.4

AREA

Square Miles Square Feet Square Inches Acre

Square Kilometers Square Meters Square Centimeters Hectare

2.59 0.0929 6.452 0.4047

VOLUME

Cubic Yards Cubic Feet Cubic Inches

Cubic Meters Cubic Meters Cubic Centimeters

0.7646 0.02832 16.39

WEIGHT

Tons (Short) Pounds Ounces (Avdp.)

Metric Tons Kilograms Grams

0.9078 0.4536 28.3495

PRESSURE

Pounds/Sq. In.

Kilopascal

6.895

WORK

Foot–Pounds

Newton–Metre

1.356

LIQUID VOLUME

Quarts Gallons

Liters Liters

0.9463 3.785

LIQUID FLOW

Gallons/Minute

Liters/Minute

3.785

TEMPERATURE

Fahrenheit

Celsius

233 of 256

DECIMALS

MULTIPLY BY

Dealer Copy -- Not for Resale

FRACTIONS

1.Subtract 32° 2. Multiply by 5/9 –8–21–

540, 543 Loader Service Manual

8–9 STANDARD TORQUE SPECIFICATIONS FOR BOLTS

THREAD SIZE INCH. LBS. (Nm)

FOOT LBS. (Nm)

SAE GRADE 5

SAE GRADE 8

.250

80–90 (9,0–10,2)

110–120 (12,4–13,6)

.3125

180–200 (20,3–22,6)

215–240 (24,2–27,1)

.375

25–28 (34–38)

35–40 (47–54)

.4375

40–45 (54–61)

60–65 (81–88)

.500

65–70 (88–95)

90–100 (122–136)

.5625

90–100 (122–136)

125–140 (170–190)

.625

125–140 (170–190)

175–190 (240–260)

.750

220–245 (300–330)

300–330 (410–450)

.875

330–360 (450–490)

475–525 (645–710)

1.000

475–525 (645–710)

725–800 (985–1085)

1.125

650–720 (880–975)

1050–1175 (1425–1600)

1.250

900–1000 (1200–1360)

1475–1625 (2000–2200)

1.375

1200–1350 (1630–1830)

2000–2200 (2720–2980)

1.500

1500–1650 (2040–2240)

2600–2850 (3530–3870)

1.625

2000–2800 (2720–2980)

3450–3800 (4680–5150)

1.750

2500–2750 (3390–3730)

4300–4800 (5830–6500)

1.875

3150–3500 (4270–4750)

5500–6100 (5830–6500)

2.000

3800–4200 (5150–5700)

6500–7200 (8800–9800)

234 of 256

–8–22–

Dealer Copy -- Not for Resale

The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from Melroe that have zinc phosphate coating are specified by the letter H following the part number.

540, 543 Loader Service Manual

ALPHABETICAL INDEX Paragraph Number 9

Dealer Copy -- Not for Resale

ALPHABETICAL INDEX . . . . . . . . . . . . . . .

Page Number 9–1

ALPHABETICAL INDEX

235 of 256

–9––1–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 236 of 256

–9–0–

540, 543 Loader Service Manual

9 ALPHABETICAL INDEX Subject

Page

A.C. Voltage, Checking the (540) . . . . . . . . . . . . . . . .6–6 Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 ..

Alternator, belt adjustment for the (543) . . . . . . . . . . 6–6 Alternator, checking the . . . . . . . . . . . . . . . . . . . . . . .6–7 .

Alternator, installing the (543) . . . . . . . . . . . . . . . . . 6–10 .

Alternator, precautions for the . . . . . . . . . . . . . . . . . . 6–3 .

Alternator, removal (543) . . . . . . . . . . . . . . . . . . . . . .6–8 .

Alternator, repairing the (543) . . . . . . . . . . . . . . . . . . 6–9 .

Alternator, System (540) . . . . . . . . . . . . . . . . . . . . . .6–6 .

Alternator, System (543) . . . . . . . . . . . . . . . . . . . . . .6–6 .

Axle and Bearings, removal . . . . . . . . . . . . . . . . . . . . 4–7 .

Axle and Bearing, assembly of the . . . . . . . . . . . . . . .4–8 Axle and Bearing, installation . . . . . . . . . . . . . . . . . . 4–9 .

Axle(s) and Bearings, removing the . . . . . . . . . . . . . .4–7 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 ...

Battery, checking the . . . . . . . . . . . . . . . . . . . . . . . . . .6–3 .

Battery, installing new . . . . . . . . . . . . . . . . . . . . . . . .1–10 .

Battery, installing the . . . . . . . . . . . . . . . . . . . . . . . . . .6–4 .

Battery, removing the . . . . . . . . . . . . . . . . . . . . . . . . .6–3 .

Battery, safety procedures for the . . . . . . . . . . . . . . . .6–3 Battery, using an extra (Booster Starting) . . . . . . . . . 1–8 Blower Housing, installing the (543) . . . . . . . . . . . .7B–13 Blower Housing, removal (543) . . . . . . . . . . . . . . . . 7B–9 .

Bob–Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–5 ..

Bob–Tach, assembly . . . . . . . . . . . . . . . . . . . . . . . . . .5–7 .

Bob–Tach, disassembly . . . . . . . . . . . . . . . . . . . . . . .5–6 .

Bob–Tach, installation . . . . . . . . . . . . . . . . . . . . . . . . .5–8 .

Bob–Tach, removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5 ..

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 ...

Camshaft (543) . . . . . . . . . . . . . . . . . . . . . . . . . . .7B–26 ..

Camshaft, inspection of the (543) . . . . . . . . . . . . . 7B–26 .

Camshaft and Tappets (540) . . . . . . . . . . . . . . . . .7A–12 .

Carburetor, assembly (540) . . . . . . . . . . . . . . . . . . .7A–6 .

Carburetor, disassembly and inspection (540) . . . . 7A–6 Carburetor, removal (540) . . . . . . . . . . . . . . . . . . . .7A–6 .

Carburetor and Fuel Shut–off Solenoid (540) . . . . . 7A–6 Chaincase Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10 ..

Chaincase Fluid, checking . . . . . . . . . . . . . . . . . . . .1–13 .

Chaincase Fluid, replacing . . . . . . . . . . . . . . . . . . . .4–10 .

Charge Pressure, checking . . . . . . . . . . . . . . . . . . . 3–19 .

Checks and Adjustments (540) . . . . . . . . . . . . . . . . 7A–3 .

Combustion Chambers, inspection (543) . . . . . . .7B–20 Compression (540) . . . . . . . . . . . . . . . . . . . . . . . . . 7A–4 ..

Connecting Rods and Bearings, inspection (543) 7B–24 Connecting Rod Bearings, inspection (543) . . . . . 7B–25 Connection, 37° flare . . . . . . . . . . . . . . . . . . . . . . . . .2–2 .

Control Pedal, adjustment . . . . . . . . . . . . . . . . . . . .2–28 .

Control Pedal, linkage and locks . . . . . . . . . . . . . . . 2–27 .

Control Pedal, installing the . . . . . . . . . . . . . . . . . . . 2–27 .

Control Pedal, removing the . . . . . . . . . . . . . . . . . . 2–27 .

Cooling System, engine . . . . . . . . . . . . . . . . . . . . . . .1–7 . ..

Crankshaft (543) . . . . . . . . . . . . . . . . . . . . . . . . . .7B–26 Crankshaft Bearing and End Play (540) . . . . . . . .7A–14 Crankshaft and Bearings, inspection (543) . . . . . . 7B–26 Cylinder Block (543) . . . . . . . . . . . . . . . . . . . . . . . 7B–23 ..

Cylinder Block, inspection (543) . . . . . . . . . . . . . . 7B–23 .

Cylinder Bores, correction of the (543) . . . . . . . . .7B–23 Cylinder Head (540) . . . . . . . . . . . . . . . . . . . . . . . 7A–15 ..

Cylinder Head (543) . . . . . . . . . . . . . . . . . . . . . . . 7B–19 ..

Cylinder Head, disassembly (543) . . . . . . . . . . . . 7B–19 .

237 of 256

–9–1–

Page

Cylinder Head, inspection (543) . . . . . . . . . . . . 7B–20 Decimal and Millimeter Equivalents . . . . . . . . . . 8–21 Detent Mechanism . . . . . . . . . . . . . . . . . . . . . . . . 2–7 ..

Drive Chains, final . . . . . . . . . . . . . . . . . . . . . . . . . 4–5 ..

Drive Chain(s), installation . . . . . . . . . . . . . . . . . . .4–6 .

Drive Chain(s), removal . . . . . . . . . . . . . . . . . . . . .4–5 .

Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–1 ..

Electrical Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . 6–2 ..

Electrical System . . . . . . . . . . . . . . . . . . . . . . 1–8, .

6–1 Electrical System Service . . . . . . . . . . . . . . . . . . . .1–8 .

Engine, assembly (543) . . . . . . . . . . . . . . . . . . 7B–30 .

Engine, blower housing and radiator (543) . . . . 7B–9 Engine, disassembly (543) . . . . . . . . . . . . . . . . .7B–17 Engine and Heat Shield (540) . . . . . . . . . . . . . . .7A–8 Engine, installing the (540) . . . . . . . . . . . . . . . . . .7A–9 Engine, installing the (543) . . . . . . . . . . . . . . . . .7B–12 Engine Oil and Filter, replacement . . . . . . . . . . . . 1–6 .

Engine Overhaul (543) . . . . . . . . . . . . . . . . . . . 7B–17 .

Engine, removal (540) . . . . . . . . . . . . . . . . . . . . 7A–8 .

Engine, removal (543) . . . . . . . . . . . . . . . . . . . 7B–11 .

Engine Service (General) . . . . . . . . . . . . . . . . . . . .1–4 .

Engine Service (540) . . . . . . . . . . . . . . . . . . . . . 7A–1 .

Engine Service (543) . . . . . . . . . . . . . . . . . . . . . 7B–1 .

Final Drive Transmission (Chaincase) . . . . . . . . 1–13 Fitting, straight thread o–ring . . . . . . . . . . . . . . . . .2–2 .

Flywheel (540) . . . . . . . . . . . . . . . . . . . . . . . . . .7A–15 .

Flywheel, engine (543) . . . . . . . . . . . . . . . . . . . 7B–33 .

Flywheel, installation (543) . . . . . . . . . . . . . . . . .7B–33 Flywheel, removal (543) . . . . . . . . . . . . . . . . . . 7B–33 .

Fuel Filter (543) . . . . . . . . . . . . . . . . . . . . . . . . . .7B–3 .

Fuel Injection Pump, Drive Gear (543) . . . . . . . 7B–4 Fuel Injection Pump, installation and timing . . . 7B–5 Fuel Injection Pump, removal . . . . . . . . . . . . . . .7B–4 Fuel Injection Pump Reservoir (543) . . . . . . . . . 7B–5 Fuel Injector Nozzles (543) . . . . . . . . . . . . . . . . .7B–6 Fuel Injector Nozzles, assembly (543) . . . . . . . . 7B–8 Fuel Injector Nozzles, checking the (543) . . . . . 7B–7 Fuel Injector Nozzles, disassembly (543) . . . . . 7B–8 Fuel Injector Nozzles, inspection (543) . . . . . . . 7B–8 Fuel Injector Nozzles, installation (543) . . . . . . . 7B–9 Fuel Lift Pump (543) . . . . . . . . . . . . . . . . . . . . . . 7B–3 .

Fuel Shut–off Solenoid (540) . . . . . . . . . . . . . . . .7A–7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–5 ..

Fuel System (543) . . . . . . . . . . . . . . . . . . . . . . . .7B–3 .

Fuel System, removing air from the (543) . . . . . 7B–3 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–11 ..

Fuel Tank, installation . . . . . . . . . . . . . . . . . . . . . .5–11 .

Fuel Tank, removal . . . . . . . . . . . . . . . . . . . . . . . 5–11 ..

Dealer Copy -- Not for Resale

Subject

Governor (540) . . . . . . . . . . . . . . . . . . . . . . . . . . .7A–7 .

Governor, installation (540) . . . . . . . . . . . . . . . . .7A–7 Governor, removal (540) . . . . . . . . . . . . . . . . . . .7A–7 Heat Shield, installation (540) . . . . . . . . . . . . . .7A–10 Heat Shield, removal (540) . . . . . . . . . . . . . . . . .7A–9 Hot Plugs, installation (543) . . . . . . . . . . . . . . . .7B–22 Hydraulic Control Valve . . . . . . . . . . . . . . . . . . . . .2–3 .

Hydraulic Control Valve . . . . . . . . . . . . . . . . . . . . .2–8 .

Hydraulic Control Valve, disassembly . . . . . . . . . .2–6

540, 543 Loader Service Manual

9 ALPHABETICAL INDEX (Cont’d) Subject

Page

Hydraulic Control Valve, installation . . . . . . . . . . . . .2–10 Hydraulic Control Valve, removal . . . . . . . . . . . . . . . .2–5 Hydraulic Cylinder, assembly . . . . . . . . . . . . . . . . . . 2–18 .

Hydraulic Cylinder, disassembly . . . . . . . . . . . . . . . 2–17 .

Hydraulic/Hydrostatic Fluid . . . . . . . . . . . . . . . . . . . 1–11 . hydraulic/Hydrostatic Fluid, checking and adding . 1–11 Hydraulic/Hydrostatic Fluid, removal . . . . . . . . . . . .1–12 Hydraulic/Hydrostatic Fluid, replacement . . . . . . . . 1–11 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10 ..

Hydraulic Pump, assembly . . . . . . . . . . . . . . . . . . . 2–13 .

Hydraulic Pump, checking output of the . . . . . . . . . 2–11 Hydraulic Pump, disassembly . . . . . . . . . . . . . . . . . 2–12 .

Hydraulic Pump, inspection . . . . . . . . . . . . . . . . . . . 2–13 .

Hydraulic Pump, installing . . . . . . . . . . . . . . . . . . . .2–15 .

Hydraulic Pump, removal . . . . . . . . . . . . . . . . . . . . .2–11 .

Hydraulic Pump, start up procedure . . . . . . . . . . . . .2–15 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 ..

Hydrostatic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9 ..

Hydrostatic Motor, assembly . . . . . . . . . . . . . . . . . . 3–14 .

Hydrostatic Motor, disassembly . . . . . . . . . . . . . . . .3–11 Hydrostatic Motor, inspection . . . . . . . . . . . . . . . . . 3–13 .

Hydrostatic Motor, installation . . . . . . . . . . . . . . . . . 3–17 .

Hydrostatic Motor, removal . . . . . . . . . . . . . . . . . . . . 3–9 .

Hydrostatic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 3–18 ..

Hydrostatic Pump, assembly . . . . . . . . . . . . . . . . . . 3–26 .

Hydrostatic Pump, disassembly . . . . . . . . . . . . . . . 3–21 .

Hydrostatic Pump, inspection . . . . . . . . . . . . . . . . . 3–25 .

Hydrostatic Pump, installation . . . . . . . . . . . . . . . . . 3–29 .

Hydrostatic Pump, removal . . . . . . . . . . . . . . . . . . . 3–20 .

Hydrostatic Pump, start–up procedure . . . . . . . . . .3–30 Ignition System (540) . . . . . . . . . . . . . . . . . . . . . . . 7A–5 ..

Information, electrical system . . . . . . . . . . . . . . . . . . 6–2 .

Information, hydraulic system . . . . . . . . . . . . . . . . . . 2–2 .

Information, hydrostatic system . . . . . . . . . . . . . . . . 3–2 .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–1 ..

Jumper Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . .5–2 .

Lift Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–3 ..

Lift Arms, installation . . . . . . . . . . . . . . . . . . . . . . . . . .5–4 .

LIft Arms, removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 ..

Lift Arm Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–16 ..

Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–15 ..

Lift Cylinder, checking . . . . . . . . . . . . . . . . . . . . . . . .2–15 .

Lift Cylinder, installing . . . . . . . . . . . . . . . . . . . . . . . .2–20 .

Lift Cylinder, removal . . . . . . . . . . . . . . . . . . . . . . . .2–16 .

Linkage, pedal lock . . . . . . . . . . . . . . . . . . . . . . . . . 2–28 ..

Linkage, throttle and governor (540) . . . . . . . . . . . .7A–4 Loading the Bobcat Loader . . . . . . . . . . . . . . . . . . . 1–15 .

Lubrication of Bobcat Loader . . . . . . . . . . . . . . . . . . 1–14 .

Lubrication System, engine . . . . . . . . . . . . . . . . . . . . 1–6 .

Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–1 ..

Manifold Assembly (543) . . . . . . . . . . . . . . . . . . . .7B–27 .

Manifold Assembly, inspection (543) . . . . . . . . . . .7B–27 Manifold, intake and exhaust (540) . . . . . . . . . . . . 7A–15 .

Muffler, cleaning the spark arrestor . . . . . . . . . . . . .1–13 Muffler, spark arrestor . . . . . . . . . . . . . . . . . . . . . . . .1–13 .

Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–24 ..

Oil Cooler, installation (540) . . . . . . . . . . . . . . . . . . . 2–25 .

238 of 256

Page

Oil Cooler, installation (543) . . . . . . . . . . . . . . . . . . . 2–26 .

Oil Cooler, removal (540) . . . . . . . . . . . . . . . . . . . . .2–24 .

Oil Cooler, removal (543) . . . . . . . . . . . . . . . . . . . . .2–25 .

Oil Filter Assembly (543) . . . . . . . . . . . . . . . . . . . .7B–28 .

Oil Filter Assembly, inspection (543) . . . . . . . . . . .7B–28 Oil Pressure (540) . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–3 ..

Oil Pump (540) . . . . . . . . . . . . . . . . . . . . . . . . . . . .7A–12 ..

Oil Pump, adjusting gear clearance for the (540) . 7A–12 Oil Pump, disassembly (543) . . . . . . . . . . . . . . . . .7B–27 .

Oil Pump, inspection (543) . . . . . . . . . . . . . . . . . . .7B–28 .

Oil Pump and Oil Filter Assembly (543) . . . . . . . . .7B–27 Oil Pump and Relief Valve (540) . . . . . . . . . . . . . . 7A–12 .

Operator Guard . . . . . . . . . . . . . . . . . . . . . . . . 1–14, .

5–1 Operator Guard, installation . . . . . . . . . . . . . . . . . . . . 5–3 .

Operator Guard, lowering . . . . . . . . . . . . . . . . . . . . . .5–1 .

Operator Guard, raising . . . . . . . . . . . . . . . . . . . . . . .5–1 .

Operator Guard, removal . . . . . . . . . . . . . . . . . . . . . .5–2 .

Parking Brake Adjustment . . . . . . . . . . . . . . . . . . . . .4–1 .

Parking Brake Inspection . . . . . . . . . . . . . . . . . . . . . .4–3 .

Parking Brake Installation . . . . . . . . . . . . . . . . . . . . .4–3 .

Parking Brake Removal . . . . . . . . . . . . . . . . . . . . . . .4–1 .

Piston and Connecting Rod, assembly (543) . . . . 7B–25 Pistons, inspection (543) . . . . . . . . . . . . . . . . . . . .7B–24 .

Pistons and Piston Rings (543) . . . . . . . . . . . . . . . 7B–23 .

Pistons and Rings, disassembly (543) . . . . . . . . . .7B–23 Piston, Rods and Crankshaft (540) . . . . . . . . . . . .7A–13 Piston, Rod and Crankshaft, removal (540) . . . . . 7A–13 Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–8 ..

Port Block, installation . . . . . . . . . . . . . . . . . . . . . . . .3–8 .

Port Block, removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8 ..

Pre–Delivery Inspection . . . . . . . . . . . . . . . . . . . . . . .1–1 .

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . .1–1 .

Push Rods and Tappets, inspection (543) . . . . . . .7B–22 Radiator, installation (543) . . . . . . . . . . . . . . . . . . .7B–16 .

Radiator, removal (543) . . . . . . . . . . . . . . . . . . . . .7B–14 .

Rear Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–9 ..

Rear Door, installing . . . . . . . . . . . . . . . . . . . . . . . . .5–10 .

Rear Door, removal (Early Model) . . . . . . . . . . . . . . .5–9 Rear Door, removal (Later Model) . . . . . . . . . . . . . . .5–9 Rear Door Latch, adjusting . . . . . . . . . . . . . . . . . . . 5–10 .

Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–3 ..

Relief Valve, checking . . . . . . . . . . . . . . . . . . . . . . . . .2–3 .

Relief Valve, installing . . . . . . . . . . . . . . . . . . . . . . . . .2–4 . .

Relief Valve, removal . . . . . . . . . . . . . . . . . . . . . . . . .2–4 Reservoir, hydraulic/hydrostatic . . . . . . . . . . . . . . . 2–23 .

Reservoir, hydraulic/hydrostatic, installation . . . . . . 2–24 Reservoir, hydraulic/hydrostatic, removal . . . . . . . . 2–23 Rocker Arms and Shaft (543) . . . . . . . . . . . . . . . . 7B–18 .

Rocker Arms, disassembly (543) . . . . . . . . . . . . . 7B–18 .

Rocker Arms, inspection (543) . . . . . . . . . . . . . . . 7B–19 .

Serial Number, engine . . . . . . . . . . . . . . . . . . . . . . . .1–1 .

Serial Number Identification . . . . . . . . . . . . . . . . . . . . 1–1 .

Serial Number, loader . . . . . . . . . . . . . . . . . . . . . . . . .1–1 .

Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 ..

Spark Plugs (540) . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–5 ..

Specifications, camshaft (540) . . . . . . . . . . . . . . . . . 8–5 .

Specifications, camshaft (543) . . . . . . . . . . . . . . . . . 8–7 .

Specifications, capacities (540) . . . . . . . . . . . . . . . . . 8–2 .

Specifications, capacities (543) . . . . . . . . . . . . . . . . . 8–4 .

–9–2–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale

Subject

9 ALPHABETICAL INDEX (Cont’d) Subject

Page

Specifications, connecting rod (540) . . . . . . . . . . . . .8–5 Specifications, connecting rod (543) . . . . . . . . . . . . .8–7 Specifications, crankshaft (540) . . . . . . . . . . . . . . . . 8–5 .

Specifications, crankshaft (543) . . . . . . . . . . . . . . . . 8–7 .

Specifications, cylinder head (543) . . . . . . . . . . . . . . .8–7 Specifications, cylinder block (543) . . . . . . . . . . . . . .8–7 Specifications, cylinder bore (540) . . . . . . . . . . . . . . .8–5 Specifications, drive system (540) . . . . . . . . . . . . . . .8–2 Specifications, drive system (543) . . . . . . . . . . . . . . .8–4 Specifications, electrical (540) . . . . . . . . . . . . . . . . . . 8–2 .

Specifications, electrical (543) . . . . . . . . . . . . . . . . . . 8–4 .

Specifications, engine (540) . . . . . . . . . . . . . . . . . . . . 8–1 .

Specifications, engine (543) . . . . . . . . . . . . . . . . . . . . 8–3 .

Specifications, engine (General) (540) . . . . . . . . . . . .8–5 Specifications, engine torque (540) . . . . . . . . . . . . . .8–6 Specifications, engine torque (543) . . . . . . . . . . . . . .8–9 Specifications, fuel injector (543) . . . . . . . . . . . . . . . .8–8 Specifications, fuel lift pump (543) . . . . . . . . . . . . . . .8–8 Specifications, hydraulic/hydrostatic fluid . . . . . . . . 8–20 Specifications, loader (540) . . . . . . . . . . . . . . . . . . . . 8–1 .

Specifications, loader (543) . . . . . . . . . . . . . . . . . . . . 8–3 .

Specifications, loader hydraulics (540) . . . . . . . . . . .8–2 Specifications, loader hydraulics (543) . . . . . . . . . . .8–4 Specifications, oil pump and relief valve (543) . . . . . 8–8 Specifications, piston (543) . . . . . . . . . . . . . . . . . . . . 8–7 .

Specifications, piston, pin and rings (540) . . . . . . . . . 8–5 Specifications, piston ring (543) . . . . . . . . . . . . . . . . 8–7 .

Specifications, tappet (543) . . . . . . . . . . . . . . . . . . . . 8–8 .

Specifications, timing gear (543) . . . . . . . . . . . . . . . . 8–7 .

Specifications, tires (540) . . . . . . . . . . . . . . . . . . . . . .8–2 .

Specifications, tires (543) . . . . . . . . . . . . . . . . . . . . . .8–4 .

Specifications, valve (543) . . . . . . . . . . . . . . . . . . . . .8–8 .

Specifications, valves, guides and tappets . . . . . . . . 8–5 Specifications, valve spring (543) . . . . . . . . . . . . . . . .8–8 Specifications, water pump (543) . . . . . . . . . . . . . . . .8–8 Stator, replacement (540) . . . . . . . . . . . . . . . . . . . . . .6–6 .

Starter (540) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–11 ..

Starter (543) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–12 ..

Starter, checking (540) . . . . . . . . . . . . . . . . . . . . . . .6–11 .

Starter, checking (543) . . . . . . . . . . . . . . . . . . . . . . .6–12 .

Starter, installation (543) . . . . . . . . . . . . . . . . . . . . .6–15 .

Starter, removal (540) . . . . . . . . . . . . . . . . . . . . . . . .6–11 .

Starter, removal (543) . . . . . . . . . . . . . . . . . . . . . . . .6–12 .

Starter, repairing (540) . . . . . . . . . . . . . . . . . . . . . . .6–11 .

Starter, repairing (543) . . . . . . . . . . . . . . . . . . . . . . .6–13 .

Steering Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 ..

Steering Levers, installation . . . . . . . . . . . . . . . . . . . . 3–4 .

Steering Levers, removal . . . . . . . . . . . . . . . . . . . . . .3–3 .

Steering Levers, repair . . . . . . . . . . . . . . . . . . . . . . . .3–4 .

Steering Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5 ..

Steering Linkage, adjustment . . . . . . . . . . . . . . . . . . 3–5 . .

Steering Linkage, installation . . . . . . . . . . . . . . . . . . . 3–7 Steering Linkage, removal . . . . . . . . . . . . . . . . . . . . .3–6 .

Stopping the Bobcat Loader . . . . . . . . . . . . . . . . . . 1–16 .

Page

Timing Gears (540) . . . . . . . . . . . . . . . . . . . . . . . . 7A–11 ..

Timing Gears (543) . . . . . . . . . . . . . . . . . . . . . . . . 7B–27 ..

Timing Gear, inspection (543) . . . . . . . . . . . . . . . . 7B–27 .

Torque, brake, axle & chaincase group . . . . . . . . . .8–15 Torque, engine group (540) . . . . . . . . . . . . . . . . . . . 8–10 .

Torque, engine group (543) . . . . . . . . . . . . . . 8–11, 8–12 Torque, hydraulic group . . . . . . . . . . . . . . . . . . . . . .8–19 .

Torque, hydrostatic group (540) . . . . . . . . . . . . . . . 8–17 .

Torque, hydrostatic group (543) . . . . . . . . . . . . . . . 8–18 .

Torque, mainframe group . . . . . . . . . . . . . . . . . . . . .8–16 .

Torque, seat bar, fuel tank and panel group . . . . . . 8–13 Torque, standard for bolts . . . . . . . . . . . . . . . . . . . .8–22 .

Torque, steering levers, linkage and pedal group . . 8–14 Transporting the Bobcat loader . . . . . . . . . . . . . . . . 1–15 .

Transport Vehicle, fastening the loader to . . . . . . . . 1–15 Troubleshooting, electrical system . . . . . . . . . . . . . . .6–1 Troubleshooting, engine service (540) . . . . . . . . . . .7A–1 Troubleshooting, engine service (543) . . . . . . . . . . .7B–1 Troubleshooting, hydraulic system . . . . . . . . . . . . . . .2–1 Troubleshooting, hydrostatic system . . . . . . . . . . . . .3–1 Tubelines & Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2 ..

U.S. to Metric Conversion . . . . . . . . . . . . . . . . . . . .8–21 .

Dealer Copy -- Not for Resale

Subject

Valve, 10 micron filter by–pass . . . . . . . . . . . . . . . . 2–26 .

Valve, by–pass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9 ..

Valve Clearance (540) . . . . . . . . . . . . . . . . . . . . . . .7A–3 .

Valve, cold weather by–pass . . . . . . . . . . . . . . . . . . 3–19 .

Valve and Guides, repair (540) . . . . . . . . . . . . . . . 7A–10 .

Valves and Guides, inspection & correction (543) 7B–20 Valves, high pressure relief replenishing function . . 3–2 Valves, checking the high pressure relief replenishing3–1 8 Valve, installation of the by–pass . . . . . . . . . . . . . . .2–27 Valves, reconditioning (540) . . . . . . . . . . . . . . . . . .7A–10 .

Valve, removing the by–pass . . . . . . . . . . . . . . . . . . 2–26 .

Valve Springs, inspection (543) . . . . . . . . . . . . . . . 7B–22 .

Valve System, assembly (453) . . . . . . . . . . . . . . . 7B–22 .

Water Pump (543) . . . . . . . . . . . . . . . . . . . . . . . . . 7B–28 ..

Water Pump, assembly (543) . . . . . . . . . . . . . . . . 7B–29 .

Water Pump, disassembly (543) . . . . . . . . . . . . . . 7B–28 .

Water Pump, inspection (543) . . . . . . . . . . . . . . . . 7B–29 .

Wire Harness, engine . . . . . . . . . . . . . . . . . . . . . . . . .6–5 .

Wire Harness, operator guard . . . . . . . . . . . . . . . . . . 6–4 .

Wire Harness, operator guard, installing . . . . . . . . . . 6–5 Wire Harness, operator guard, removal . . . . . . . . . . .6–4

Thirty Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . .1–2 .

Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–21 ..

Tilt Cylinder, checking . . . . . . . . . . . . . . . . . . . . . . . .2–21 .

Tilt Cylinder, installation . . . . . . . . . . . . . . . . . . . . . .2–23 .

Tilt Cylinder, removal . . . . . . . . . . . . . . . . . . . . . . . . .2–22 .

Timing Cover (540) . . . . . . . . . . . . . . . . . . . . . . . . 7A–11 ..

Timing Cover, Timing Gears and Camshaft (540) 7A–11

239 of 256

–9–3–

540, 543 Loader Service Manual

Dealer Copy -- Not for Resale 240 of 256

–9–4–

540, 543 Loader Service Manual

540–1 ®

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT LOADER Model

540 and 543

Revision Number

23 August 1982 Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6566181 (11–81)

NOTICE

Insert This Sheet With The Above Listed Manual For Future Reference.

Dealer Copy -- Not for Resale

Please make the following changes to correct your Service Manual.

Page 5–8, Paragraph 5–3.4, Step 3. Write in the correct torque for tightening the pivot pin bolt, 125–140 ft.–lbs. (170–190 Nm).

Page 8–16, Paragraph 8–5.7, Reference 9. Write in the correct torque, 125–140 ft.–lbs. (170–190 Nm).

Remove the chart which shows the Operator’s Guard Wiring Diagram (the first page following the Electrical System contents page–Section 6). Insert the new chart, ROPS Wiring Diagram.

Printed in U.S.A. 241 of 256

242 of 256

Dealer Copy -- Not for Resale

540–2 ®

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT LOADER Model

540 and 543

Revision Number

23 March 1983 Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6566181

NOTICE

Insert This Sheet With The Above Listed Manual For Future Reference.

Dealer Copy -- Not for Resale

The attached Hydraulic/Hydrostatic Charts were not originally included in the 540 Service Manual Publication Number 6566181.

These charts should be filed in your 540 Service Manual. The Systems Operation and Hydraulic Chart should be filed before Page 2–1. The Hydrostatic Neutral and Forward Charts should be filed before Page 3–1.

Four adhesive labels have been attached to this letter. These labels are the Serial Number Breaks for these Charts. Please apply them to the heading of each chart and the System Operation.

Additional charts may be ordered from Publications Dept., Melroe Division, Clark Equipment, Gwinner, N.D. 58040.

Printed in U.S.A. 243 of 256

244 of 256

Dealer Copy -- Not for Resale

540–2 ®

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT LOADER Model

540 and 543 (S/N 11999 & Below)

Revision Number

8 August 83 Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6566181 (11–81)

NOTICE

Insert This Sheet With The Above Listed Manual For Future Reference.

Dealer Copy -- Not for Resale

Please make the following changes to correct your Service Manual.

Page 3–28, Paragraph 3–7.7, step (14) and step (16). W rite in correct torque for tightening pump housing bolts, “42 ft.–lbs.

(57 Nm) torque”.

Printed in U.S.A. 245 of 256

246 of 256

Dealer Copy -- Not for Resale

540–3 ®

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT LOADER Model

540, 543 (S/N 11999 & Below)

Revision Number

15 November 1989 Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6566181 (11–81)

NOTICE

Insert This Sheet With The Above Listed Manual For Future Reference.

Take out and put in the revised pages as listed below: TAKE OUT

PUT IN

4–9, 4–10

4–9 (Revised Nov. 89), 4–10 (Revised Nov. 89)

5–7, 5–8

5–7, 5–8 (Revised Nov. 89)

8–5, 8–6 8–7, 8–8 8–15, 8–16

8–5 (Revised Nov. 89), 8–6 8–7 (Revised Nov. 89), 8–8 (Revised Nov. 89) 8–15 (Revised Nov. 89), 8–16 (Revised Nov. 89)

Dealer Copy -- Not for Resale

This is a revision to the 540, 543 Service Manual (6566181).

Printed in U.S.A. 247 of 256

248 of 256

Dealer Copy -- Not for Resale

540–4 Revision Number

®

30 June 1994

SERVICE MANUAL REVISION

Date

ROUTE TO ATTENTION

AFFECTING: Product BOBCAT LOADER Model

PARTS MANAGER SERVICE MANAGER SALES MANAGER

540, 543 (S/N 11999 & Below)

X

Manual No. 6566181 (11–81)

NOTICE

Insert This Sheet With The Above Listed Manual For Future Reference.

Take out the pages shown and put in the revised pages as follows: TAKE OUT

PUT IN

1–5, 1–6

1–5, 1–6 (Revised June 94)

2–11, 2–12

2–11 (Revised June 94), 2–12

3–27, 3–28

3–27 (Revised June 94), 3–28 (Revised June 94)

ENGINE WIRING DIAGRAM (540)

ENGINE WIRING DIAGRAM (540) (Revised June 94)

ENGINE WIRING DIAGRAM (543)

ENGINE WIRING DIAGRAM (543) (Revised June 94)

Dealer Copy -- Not for Resale

The following pages are a revision to the 540, 543 Service Manual P/N 6566181 (11–81).

Printed in U.S.A. 249 of 256

250 of 256

Dealer Copy -- Not for Resale

540–5 Revision Number

®

2 August 1994

SERVICE MANUAL REVISION AFFECTING: Product BOBCAT LOADER Model

Date

ROUTE TO ATTENTION PARTS MANAGER SERVICE MANAGER SALES MANAGER

540, 543 (S/N 11999 & Below)

X

Manual No. 6566181 (11–81)

NOTICE

Insert This Sheet With The Above Listed Manual For Future Reference.

Take out the pages shown and put in the revised pages as follows: TAKE OUT

PUT IN

ENGINE WIRING DIAGRAM (540)

ENGINE WIRING DIAGRAM (540) (Revised August 94)

ENGINE WIRING DIAGRAM (543)

ENGINE WIRING DIAGRAM (543) (Revised August 94)

Dealer Copy -- Not for Resale

The following pages are a revision to the 540, 543 Service Manual P/N 6566181 (11–81)

Printed in U.S.A. 251 of 256

252 of 256

Dealer Copy -- Not for Resale

540–6 ®

Revision Number

30 October 1998

SERVICE MANUAL REVISION

Date

ROUTE TO ATTENTION

AFFECTING: Product BOBCAT LOADER 540 (S/N 501011999 & Below) 543 (S/N 501111999 & Below) Model

PARTS MANAGER SERVICE MANAGER SALES MANAGER

X

Manual No. 6566181 (11–81)

NOTICE

Insert This Sheet With The Above Listed Manual For Future Reference.

TAKE OUT

PUT IN

COVER

COVER MAINTENANCE SAFETY Page (Place Behind Cover)

SAFETY INSTRUCTION Page (Located Behind Foreword)

SAFETY INSTRUCTION Page (Located Behind Foreword)

1–7 thru 1–16

1–7 thru 1–16

2–3, 2–4 2–29

2–3, 2–4 2–29

6–1 thru 6–4

6–1 thru 6–4

Dealer Copy -- Not for Resale

Take out the following pages and put in the revised and added pages as follows:

Printed in U.S.A. 253 of 256

254 of 256

Dealer Copy -- Not for Resale

ROUTE TO ATTENTION

SERVICE MANUAL REVISION

NOTICE

Insert This Sheet With The Below Listed Manual For Future Reference.

540/543-7 15 June 2012 Bobcat Loader 540/543 6566181 (11-81)

The following Sections are a revision to the above Service Manual.

COVER

255 of 256

X

SMR-1

Dealer Copy -- Not for Resale

Revision No: Date: Product: Model: Manual No:

PARTS MANAGER SERVICE MANAGER SALES MANAGER

256 of 256

SMR-2

Dealer Copy -- Not for Resale