4 DRIVE SYSTEM

4–1 BRAKES

Always stop the engine and engage the parking brake before you leave the operator’s seat.

1/4” (6,35 mm)

4–1.1 Parking Brake Adjustment

When the brakes are in good condition and adjusted correctly, they will keep the loader from moving when in the parked position.

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.

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 counterclockwiseuntil 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).

2.Remove the front panel (Fig. 4–4).

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).

5.Remove the brake linkage from the pedal.

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).

Important

Be careful not to cause damage to the gaskets.

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.

11.Loosen the bolt on the hydrostatic motor (Fig. 4–11). Remove the disc tool.

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.

14.Remove the brake block from the transmission cover (Fig. 4–15).

15.Remove the brake pucks (Fig. 4–16) from the brake block.

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.

3.Check for a good fit between the pucks and the bore in the block. They must be free to slide in the block.

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. B–05179

Brake Disc

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).

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).

6.Install the brake discs on the sprocket teeth (Fig. 4–21).

8.Install the disc special tool and tighten the sprocket bolt to 260–300 ft.–lbs. (352–407 Nm) torque.

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).

15.Install the hydraulic pumps (See Paragraph 3–7.8, Page 3–29).

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).

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).

4–2.2 Installing the Drive Chain(s)

The tools listed will be needed to do the following procedure:

MEL–1037 Chain Link Press Tool

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.

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.

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).

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.

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).

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).

10.Move the sprocket away from the

11.Using a long punch, removethe inside bearing cup (Fig. 4–32).

12.Using a bearing puller tool and slide hammer (Fig. 4–33) remove the outer bearing cup.

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.

1.Lubricate

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 Bearing Installation

The tools listed will be needed to do the following procedure:

MEL–1051 Axle Seal Tool

MEL–1202A Axle Bearing Race Set

1.Using a bushing driver, install the outer bearing cup (Fig. 4–38).

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.

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–03981

Fig. 4–36 Installing Outer Bearing

B–03982

Fig. 4–38 Installing Bearing Cup

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).

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.

12.Remove the spring from the installation tool.

B–03984

Fig. 4–37 Installing Outer Bearing

B–02770

Fig. 4–39 Installing Inner Halves of Tool

B–02774

Fig. 4–40 Installing Outer Halves of Tool

Fig. 4–41 Installing Spring

B–02772

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).

17.Install the transmission cover/brake assembly (See Paragraph 4–1.4).

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.

4.Use a pump (Fig. 4–42) to remove the fluid from the 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).

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 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).

Warning

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.

5.Remove the two (2) bolt assemblies (including washers) at the frontcorners of the operator guard (Fig. 5–2).

6.Two (2) persons are needed to lift the operator guard. Avoid slippery surfaces when lifting the operator guard.

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

1.Stop the engine and remove the jumper start switch.

2.Two (2) persons are needed to lower the operator guard. Avoid slippery surfaces when lowering the operator guard.

3.Stand on the ground, one person on each side and pull down on theoperator 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.

4.Pull the ring on the cable (Fig. 5–5) while thesecond 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). Tighten 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.

5–1.3 Jumper Start Switch

The tool listed will be needed to do the following procedure:

MEL–1138 Jumper Start Switch

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.

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).

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.

5.Install the nuts and tighten to 25–35 ft.–lbs. (34–47 Nm) torque (Fig. 5–9).

6.Install the spring blocks. Install the bolts in the spring blocks and tighten to 65–70 ft.–lbs. (88–95 Nm) torque.

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

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.

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).

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.

11.Raise the lift arms, with the chain hoist and remove the lift arms from the loader.

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).

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).

2.Stop the engine. Activate the hydraulic controls to release the hydraulic pressure from the system.

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.

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.

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.

8.Remove the bolt and use a punch to push the pivot pin into the Bob–Tach frame.

9.Remove the Bob–Tach from the lift arms. 5–3.2 Disassembly of the Bob–Tach

1.Put the Bob–Tach on the work bench.

2.Remove the Bob–Tach 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).

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.

8.Remove the plastic guides from the Bob–Tach frame (Fig. 5–30).

9.Clean and inspect all the parts for wear and damage. Replace the parts as needed.

Fig. 5–29 Removing the Nut

B–04553

Fig. 5–28 Wedge Block

B–04554

B–04556

5–3.3 Assembly of the Bob–Tach

1.Install the spring on the wedge bolt. Install the nut (Fig. 5–31).

B–04875

Fig. 5–30 Removing Plastic Guides

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).

3.Tighten the nut to 65–70 ft.–lbs. (88–95 Nm) torque to lock the block into position.

Fig. 5–31 Installing the Spring

B–04556

6.09–6.21” (155–158 mm)

Fig. 5–32 Installing the Block

B–04554

4.Install the lever and bolt and tighten the bolt to 25–28 ft.–lbs. (34–38 Nm) torque (Fig. 5–33).

5.Install the new plastic guides in the Bob–Tach frame (Fig. 5–34).

B–04557

Fig. 5–33 Tightening the Lever Bolt

B–04875

Fig. 5–34 Installing Plastic Guides

5

6.Using a punch and hammer, install the wedges and lever assembly in the Bob–Tach 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).

8.Install the pivot pin in the Bob–Tach frame (Fig. 5–37), the tapered area facing out.

5–3.4 Installing the Bob–Tach

1.Put the Bob–Tach between the lift arms.

2.Using a punch, push the pivot pin into the lift arms (Fig. 5–38) from the grease fitting hole.

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).

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

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.

5–4 REAR DOOR

5–4.1 Removing the Rear Door (Early Model)

1.Open the rear door.

5–41 Installing Pivot Pin

2.Remove the retainer bolt at the bottom hinge on the door (Fig. 5–43).

5–42 Tightening the Bolt

3.Lift the rear door from the loader main frame (Fig. 5–44).

NOTE:On the 540 loader the oil cooler hoses will have to be removed (See Paragraph 2–8.1, Page 2–24).

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.

B–05115

2.Install a chain hoist on the rear door (Fig. 5–45).

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.

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.

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.

5–5 FUEL TANK

5–5.1 Removing the Fuel Tank

1.Raise the lift arms and install a lift arm stop (See Paragraph 1–11, Page 1–16). Stop the engine.

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

3.Disconnect the wire from the connector in the operator guard (Fig. 5–50).

4.Put the wire in the tank area (Fig. 5–51).

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).

5–5.2 Installing the Fuel Tank

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.

STARTER (540)

STARTER (543)6–96–12

TROUBLESHOOTING6–16–1

WIRE HARNESS FOR THE ENGINE

WIRE HARNESS FOR THE OPERATOR GUARD6–46–4

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.