PDF DOWNLOAD Bobcat 543 Operation & Maintenance Manual 6722584

5 4 3

Operation & Maintenance Manual (S/N 502420001 & Above)

6722584 (3–93) Revised (11–98)

Printed in U.S.A.

© Melroe Company 1998

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540, 543 Loader Service Manual

CONTENTS FOREWORD FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 MACHINE SIGNS TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

SAFETY

OPERATING INSTRUCTIONS

REFERENCE INFORMATION Write the correct information for Your Bobcat loader in the spaces below. Always use these numbers when referring to your Bobcat loader.

PREVENTIVE MAINTENANCE

Loader Serial Number . . . . . . . .

Engine Serial Number . . . . . . . .

SYSTEMS ANALYSIS NOTES:

MACHINE SIGN TRANSLATIONS

SPECIFICATIONS

YOUR LOADER DEALER: ADDRESS: PHONE:

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543 Bobcat Loader Operation & Maintenance Manual

FOREWORD FOREWORD This Operation & Maintenance Manual was written to give the owner/operator necessary operating, servicing and preventive maintence instruction for the Bobcat loader.

For any extra information needed, see your Bobcat Loader dealer.

Do not do any service procedures that are not in the OPERATION AND MAINTENANCE MANUAL! Only service procedures that are not in the Operation & Mainenance Manual.

If extra Parts Books, Service Manuals or Operation & Maintenance are needed, they are available through the Bobcat dealer in your area for an added cost.

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

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SERIAL NUMBER LOCATIONS

A

Always use the serila number of the loader when requesting service inofrmation or when ordering parts.

Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

LOADER SERIAL NUMBER The loader serial number plate is located on the inside of the left upright, above the rear grill [A].

Explanation of loader Serial Number: XXXX

P–1670

XXXXX

B

Production Sequence (Series)

1

Model, Engine Version ENGINE SERIAL NUMBER The serial number (Item 1) is located at the fuel injuction pump side on the engine block [B].

P–1671

C

DELIVERY REPORT The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [C].

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543 Bobcat Loader Operation & Maintenance Manual

BOBCAT LOADER IDENTIFICATION SEAT BAR

D OPERATOR CAB (ROPS & FOPS)

REAR LIGHT

UPRIGHTS

LIFT ARM LIFT CYLINDER

GRILL

REAR DOOR *TIRES

FRONT LIGHTS GRAB HANDLES

UPRIGHTS OPERATOR SEAT

STEERING LEVER SEAT BELT

SAFETY TREAD

TILT CYLINDER QUICK COUPLERS BUCKET STEPS

{ BUCKET * { D

B–12556 B–7377

TIRES – Flotation tires are shown. The Bobcat loader is based–equipped with standard tires.

BUCKET – Several different buckets and other attachments are available for the Bobcat loader.

ROPS, FOPS – Roll–Over Protective Structure, Falling Object Protective Structure, per SE J1040 and SAE J1043. The Bobcat loader is base–equipped with a standard operator cab as shown.

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543 Bobcat Loader Operation & Maintenance Manual

SAFETY SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi MACHINE SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii, xiii

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543 Bobcat Loader Operation & Maintenance Manual

SAFETY INSTRUCTIONS SAFETY IS THE OPERATOR’S RESPONSIBILITY The Skid Steer Loader is a highly maneuverable and compact machine. In operation, it is rugged and useful under a wide variety of conditions. This presents an operator with hazards associated with off highway, rough terrain applications. The loader has an internal combustion engine with resultant heat and exhaust. All exhaust gases can kill or cause illness so the loader must be used with adequate ventilation. The loader has a spark arrestor muffler which is required for operation in certain areas.

The dealer explains the capabilities and restrictions of the loader and attachments for each application. The dealer demonstrates the safe operation of the loader according to Melroe’s instructional materials; which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments. The attachments and buckets are designed for rated capacity and secure fastening to the loader. The user must check with the dealer, or Melroe Company literature, to determine safe loads of materials of specified densities for his loader–attachment combination.

The following publications provide information on the safe use and maintenance of the loader and attachments: • The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.

• The Operation and Maintenance Manual delivered with the loader gives operating information as well as routine maintenance and service procedures. It is a part of the loader and can be stored in a container (later models) provided inside the cab. Replacement Operation and 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 and Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.

• The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.

• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.

• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and repair work.

• The Skid–Steer Loader Operator Training Course is available through your local Bobcat dealer. This course provides information for safe and efficient operation of the Bobcat loader. The course is available in English and Spanish versions.

• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

The dealer and owner/operator review the recommended uses of the loader and attachments when the loader is delivered.

If the owner/operator will be using the loader for a different application(s) he must ask the dealer for recommendations on the new use.

Call Before You Dig 1–888–258–0808 When you call, you will be directed to a location in your state/city for information about burried lines (telephone, cable TV, water, sewer, gas,etc.).

SI01–0698

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543 Bobcat Loader Operation & Maintenance Manual

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

Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W–2001–1285 B–10731

The Bobcat loader must be in good operating condition before use.

Check all of the items on the Service Schedule under the 8–10 hour column or as shown in this Manual.

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

SAFE OPERATION NEEDS A QUALIFIED OPERATOR* A QUALIFIED OPERATOR MUST DO THE FOLLOWING:

• UNDERSTAND THE WRITTEN INSTRUCTIONS, RULES AND REGULATIONS • The written instructions from Melroe Company include the Delivery Report, Operation & Maintenance Manual, Operator’s Handbook, EMI Safety Manual and machine signs (decals).

• Check the rules and regulations at your location. The rules may include an employer’s work safety requirements.

Regulations may apply to local driving requirements or use of Slow Moving Vehicle emblem. Regulations may identify a hazard such as a utility line.

• HAVE TRAINING WITH ACTUAL OPERATION • Operator training must consist of a demostration and verbal instruction. This training is given by your dealer before the loader is delivered.

• The new operator must start in an area without bystanders and use all the controls until he can operate the loader safely under all conditions of the work area. Always fasten seat belt and lower seat bar before operating.

• The Skid Steer Loader Operator Training Course is available in English and Spanish. The course provides information for safe and efficient operation. See your dealer for availability.

• KNOW THE WORK CONDITIONS • For each material to be handled, the operator must know how to avoid exceeding the rated operating capacity of the loader. For example, in handling certain loose material with a given bucket, he must know whether he can safely take a full load, or only part of a bucket load.

• The operator must know any prohibited uses or work areas, for example, he needs to know about excessive slopes.

• Know the location of any underground lines. Call local utilities or the TOLL FREE phone number found in the SAFETY INSTRUCTIONS Section of this manual.

• 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 about Melroe Safety equipment.

* For an operator be qualified, he must not use drugs or alcoholic drinks which impair his alertness or coordination while working. An operator who is taking prescription drugs must get medical advice to determine if he can safely operate a machine.

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543 Bobcat Loader Operation & Maintenance Manual

FIRE PREVENTION The loader has several components that are at high temperature under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will increase the fire hazard. The loader must be cleaned as often as necessary to avoid this accumulation. Flammable debris in the engine compartment is a fire hazard when the loader is parked with a hot engine.

The spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot.

• Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive 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 any damaged part.

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

• Do not use ether or starting fluids on this engine. It has glow plugs. These starting aids can cause explosion and injure you or bystanders.

• 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 welding 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 Manual for connecting the battery.

• Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler.

• Know where fire extinguishers and first aid kits are located and how to use them.

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

A

P–10650

SI03–0398

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543 Bobcat Loader Operation & Maintenance Manual

MACHINE SIGNS (DECALS) Follow the instructions on all the Machine Signs (Decals) that are on the loader. Replace any damaged machine signs and be sure they are in the correct locations. Machine signs are available from your Bobcat dealer.

6557565

6569119 6565959 (6 Lang. Opt.)

6577754

6557569

6569021

6579639

6579509 6579510

6579528 B–7377

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MACHINE SIGNS (DECALS) (Cont’d) Follow the instructions on all the Machine Signs (Decals) that are on the loader. Replace any damaged machine signs and be sure they are in the correct locations. Machine signs are available from your Bobcat dealer.

6560573

6561379

6565990

6567875 6579511

B–12556

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543 Bobcat Loader Operation & Maintenance Manual

OPERATING INSTRUCTIONS ATTACHMENTS & BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Installation And Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENGINE STOP CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 GETTING READY FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

OPERATING INSTRUCTIONS

HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Auxiliary Hydraulics Operation (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Tilt Operation (Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 OPERTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Emptying The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Digging Into The Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Filling The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Leveling The Ground (Using Lift Arms In Float Postion) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PARKING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cold Temperature Starting Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Normal Starting Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Warming The Hydraulic/Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . 13 STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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543 Bobcat Loader Operation & Maintenance Manual

INSTRUMENT PANEL

A

The instrument panel has the following instruments [A].

10

5

3 1

1. LIGHT SWITCH (OPT.) – Controls the work and travel lights.

6

2. IGNITION SWITCH – For starting, stopping and ‘‘pre–heating’’ the engine.

7

4

3. FUSE (ACCESSORIES) – To protect the electrical system from overload.

2 8

4. FUSE (IGNITION) – To protect the electrical system from overload.

9 B–12526

5. HOURMETER – Records the total operating hours of the loader.

B

6. FUEL GAUGE – Shows the amount of fuel in the fuel tank.

1

7. ENGINE TEMPERATURE GAUGE – Shows the engine coolant temperature.

8. ENGINE WARNING LIGHT – Engine oil pressure is low. Stop the engine if the light comes ‘‘ON’’.

9. TRANSMISSION WARNING LIGHT – Low transmission charge pressure, hydraulic filter needs replacement or high fluid temperature. Stop the engine if the light comes ‘‘ON’’.

2

B–7467

10. VOLTMETER – Shows the condition of the battery and the rate of charge.

ENGINE SPEED CONTROL The engine speed control (Item 1) is at the right side of the operator’s seat. Engine speed is controlled by moving the engine speed control forward to increase the engine RPM and backward to decrease the engine RPM [B].

ENGINE STOP CONTROL The engine stop control (Item 2) is located near the engine speedcontrol. Pull up on the engine stop control to stop the engine. Push down on the control after the engine is stopped [C].

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543 Bobcat Loader Operation & Maintenance Manual

PARKING BRAKE

A

Lock the parking brake by pushing down on the top (toe) of the pedal [A].

B–3744

B–7378

To release the parking brake, push down on the bottom (heel) of the pedal [B].

B

B–3745

B–5717

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543 Bobcat Loader Operation & Maintenance Manual

STEERING LEVERS

A

1

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

W–2046–0595

B–7379

The steering levers (Item 1) are on the right and left side in front of the seat [A].

For safe control of the loader always move the levers slowly and smoothly. Only a small movement is necessary to move the loader.

B

FORWARD BACKWARD

The steering levers control forward and reverse travel of the loader [B].

FORWARD TRAVEL: Push both levers forward.

REVERSE TRAVEL: Pull both levers backward.

NORMAL TURNING: Move one lever farther forward than the other.

FAST TURNING: Push one lever forward and pull the other lever backward.

For slow travel speed, push the levers forward only a small amount.

LEFT TURN

RIGHT TURN

FAST TURN

FAST TURN

To increase travel speed, push the levers farther forward.

For maximum pushing force, push the levers forward only a small amount with the engine at full RPM.

PI–1849

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543 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS

A

Foot Pedals

3 1 2

B–7379

Keep both feet on pedals while operating machine. Failure to do so can cause serious injury.

W–2002–1285

Put your feet on the pedals and KEEP THEM THERE any time you operate the loader.

Two foot pedals (Item 1) control the hydraulic cylinders for the tilt and lift function [A].

Lift Arm Operation The left pedal controls the lift arms. Push on the bottom (heel) (Item 2) of the pedal to raise the lift arms [A]..

Push on the top (toe) (Item 3) of the pedal to lower the lift arms [A]. Use the ’’Float’’ position of the lift arms to level loose material while driving backward.

4 1

The optional bucket position valve, will keep the bucket at a level position when the lift arms are being raised.

5

B–7379

Tilt Operation (Bucket) The right pedal controls the action of the bucket. Push the top (toe) (Item 4) of the pedal to tilt the bucket forward [A].

Push the bottom (heel) (Item 5) of the pedal to tilt the bucket backward [A].

B–7440 B–7441

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543 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d)

A

Auxiliary Hydraulics Operation (Optional) The right steering lever is also the control lever for the front auxiliary hydraulics [A].

P–0149

Move the right steering lever to the left or to the right to activate the auxiliary hydraulics and operate an attachment (Example: To open or close grapple teeth).

Move the lever in the opposite direction to reverse the action of the attachment [B].

B

Move the steering lever all the way to the right (Item 1) to put the control valve into the ‘‘detent’’ position for a constant flow of hydraulic fluid under pressure to the quick couplers [B].

B–2408

B–2409

NOTE: See Page 46 to remove auxiliary control lobolt.

1

B–7379

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543 Bobcat Loader Operation & Maintenance Manual

DAILY INSPECTION

A

The loader must be in good operating condition [A].

Check the following items: * Engine Oil * Hydraulic/Hydrostatic Fluid * Air Cleaner Condition Indicator * Engine Cooling System * * Operator Cab, Seat Belt, Seat Bar & Pedal Interlocks * Lift Arms & Cylinder Pivot Pins * Tires & Tire Pressure * Any Loose or Broken Parts * Safety Tread & Safety Signs Follow the maintenance requirements on the Service Schedule Decal, located inside the rear door [B].

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.

B–6583 B–6592

W–2003–0797

B

6567875

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543 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM

A

The seat bar restraint system has a pivoting seat bar (Item 1) with arm rests and has spring loaded interlocks for the lift and tilt control pedals. The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat. The interlocks require the operator to lower the seat bar in order to operate the foot pedal controls. When the seat bar is up, the lift and tilt control pedals are locked when returned to the neutral position [A].

1

P–1718

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

W–2046–0595

B The spring loaded interlocks (Item 1) control the locking and unlocking functions of the control pedals [A].

2

Seat Bar

The interlocks (Item 1) require the operator to lower the seat bar (Item 2) which allows the operator to move the foot pedals to control the lift and tilt functions [B].

Interlock

When the seat bar is lowered, it pushes the interlock (Item 1) down on both sides, releasing the pedal linkages (Item 3) from the interlocks [B].

1 Pedal Linkage

The pedals now pivot in both directions when the interlock is down.

3

AVOID INJURY OR DEATH

MC–1669

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

C Seat Bar

W–2045–1086

AVOID INJURY OR DEATH The seat bar system must lock the lift and tilt control pedals in neutral when the seat bar is up. Service the system if pedals do not lock correctly.

Interlock

W–2105–1285

When the seat bar is raised, spring forces raise the interlocks [C].

The foot pedals will not pivot when the interlock is up.

Refer to the Preventive Maintenance section for Seat Bar Restraint System Inspection & Maintenance.

MC–1669

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543 Bobcat Loader Operation & Maintenance Manual

GETTING READY FOR OPERATION

A

Read this Operation & Maintenance Manual and the Operator’s Handbook before operating the loader [A].

Operator must have instructions before running the machine. Untrained operators can cause injury or death.

W–2001–0596 B–7377

Use the bucket or attachment steps, grab handles and safety tread (on top of the loader lift arm crossmember and main frame) to get on and off the loader [B].

B

Safety treads are installed on the Bobcat loader to provide a slip resistant surface for getting on and off the loader.

Keep the safety treads clean and replace when damaged.

Replacement treads are available from your dealer.

B–12885

Pull the seat lever (Item 1) and adjust the seat position for comfortable operation of the loader controls [C].

C

1 B–3878

Fasten the seat belt snugly and adjust it so that the buckle is centered between the hips [D].

D

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

W–2046–0595 C–2596

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B–12377

543 Bobcat Loader Operation & Maintenance Manual

GETTING READY FOR OPERATION (Cont’d)

A

Lower the seat bar [A].

Be sure the parking brake is engaged.

All controls must be in the neutral position before you start the engine (See ‘‘Normal Starting Condition’’, Page 9).

B–12378

Keep feet on the pedals while seated in the loader [B].

B

STARTING THE ENGINE B–12379

C

WRONG

When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside.

Exhaust fumes contain odorless, invisible gases which can kill without warning.

W–2050–1285

AVOID INJURY OR DEATH • Engines can have hot parts and hot exhaust gas. Keep flammable material away.

B–3724

• Do not use machines in atmosphere containing explosive gas.

W–2051–1086

D

WRONG

Normal Starting Condition Adjust the seat position for comfortable operation of the foot pedals and steering levers.

Fasten the seat belt snugly and adjust it so the buckle is centered between the hips.

B–6578

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543 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Lower the seat bar [A]..

B–6579

Put the foot pedals and steering levers in neutral (center) position (Item 1) [B].

B

Be sure the parking brake is engaged.

NEUTRAL POSITION

Set the engine speed control to the half speed position (Item 2) [B].

Turn the key to the ‘‘ON’’ position. The engine and transmission warning lights must be ‘‘ON’’ when the key is on and the engine is stopped (Item 3) [B].

1 1/2 THROTTLE

Turn the key to the start position (Item 4) and release it when the engine starts [B].

2 ”ON” POSITION Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Cool the starter for one minute between uses.

I–2034–0284

3

When the engine starts, release the key and it will return to the run position (Item 5) [B].

”START” POSITION

STOP THE ENGINE IF THE WARNING LIGHTS DO NOT GO OFF. In cold starting conditions, turn the key all the way to the left for ‘‘PRE–HEAT’’ position (Item 6) [B]. See also Cold Starting Condition, Page 11.

4 ”RUN” POSITION

5 ”PREHEAT’ POSITION

6 –12–

PI–2188

543 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Cold Temperature Starting Condition If the temperature is below 32F. (0C.), use the following procedure to make starting the engine easier: 1. Replace the engine oil with the correct type and viscosity for the anticipated starting temperature (See ‘‘Oil Specifications’’, Page 31).

2. Make sure the battery is at full charge.

3. Install a block or tank heater on the engine.

Follow the steps under ‘‘Normal Starting Condition’’ and repeat the ’’Pre–Heating’’ procedure until the engine starts [A].

6565927

Do not use ether with glow plug (preheat) systems. Explosion can result which can cause injury or death.

W–2071–1285

Warming The Hydraulic/Hydrostatic System Let the engine run for a minimum of 5 minutes to warm the engine and hydrostatic transmission fluid before operating the loader. If the warning light comes ‘‘ON’’ when operating the loader (cold), more warm up time is needed.

STOPPING THE ENGINE Pull the engine speed control fully backward to decrease the engine RPM. Turn the key switch to the ‘‘OFF’’ position.

Pull up on the engine stop control to stop the engine. Push down on the engine stop control after the engine has stopped.

–13–

543 Bobcat Loader Operation & Maintenance Manual

ATTACHMENT AND BUCKETS

A

Never use attachments or buckets which are not approved by Melroe Company. Buckets and attachments for safe loads of specified densities are approved for each model.

Unapproved attachments can cause injury or death.

W–2052–1285

The dealer can identify, for each model loader, the attachments and buckets approved by Melroe Company.

The buckets and attachments are approved for Rated Operating Capacity and for secure fastening to the Bob–Tach.

B–6587

The Rated Operating Capacity for this loader is shown on a label in the operator cab (See the ‘‘Specifications’’ section, Page 57).

It is determined by using a standard dirt bucket, and material of normal density, such as dirt or dry gravel. If longer buckets are used the load center moves forward and reduces the Rated Operating Capacity. If very dense material is loaded, the volume must be reduced.

AVOID INJURY OR DEATH Do not exceed rated operating capacity.

Excessive load can cause tipping or loss of control.

Exceeding the Rated Operating Capacity can cause the following problems [A].

W–2053–0887

1. Steering the loader may be difficult.

B

2. Tires may wear faster.

WEIGHT OF LOADS LBS. (KG)

3. There will be a loss of stability.

4. The life of the Bobcat loader will be reduced.

Use the correct size bucket for the type and density of material being handled. For safe handling of materials and avoiding machine damage, the attachment (or bucket) should handle a full load without going over the Rated Operating Capacity for the loader. Partial loads make steering more difficult.

Maximum loads to be carried when using a pallet fork are shown in figure [B].

3 (76)

23 (584)

45 (1143)

CENTER OF LOAD LOCATION Inches (mm)

543 MODEL 6558413

–14–

543 Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS (Cont’d)

A

Installation And Removal The loader is equipped with a Bob–Tach system. The Bob–Tach is used for fast changing of buckets and attachments. See the attachments Operator’s Manual to install other attachments.

PI–2590 B–3851

Bob–Tach levers have spring tension. Hold lever tightly and release slowly. Failure to obey warning can cause injury.

W–2054–1285

B

Pull the Bob–Tach levers all the way up.

Tilt the Bob–Tach forward. Drive the loader forward until the top edge of the Bob–Tach is completely under the flange of the bucket [A].

DO NOT hit the Bob–Tach levers on the bucket.

Tilt the Bob–Tach backward until the bucket is off the ground and stop the engine [B]..

PI–2591 B–3850

C

AVOID INJURY OR DEATH Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

W–2045–1086

Push down on the Bob–Tach levers until they are in the locked position [C].

B–3852 B–7018

D Keep the rear door closed when operating the machine. Failure to do so could seriously injure a bystander.

W–2020–1285

The wedges (Item 1) must extend through the holes in the bucket or attachment [D].

Removal: Reverse the above procedure to remove the bucket or attachment from the Bob–Tach.

1 B–3893

–15–

543 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES

A

Always warm up the engine and hydrostatic system before operating the loader.

WITH BUCKET FULL

Machines warmed up with moderate engine speed and light load have longer life.

I–2015–0284

Going Up Slope Operate the loader with the engine at full speed for maximum horsepower. Move the steering levers only a small amount to operate the loader slowly.

B

B–6612

WITH BUCKET FULL

New operators must operate the loader in an open area without bystanders. Operate the controls until the loader can be handled at an efficient and safe rate for all conditions of the work area.

With a full bucket, go up or down the slope with the heavy end toward the top of the slope [A] & [B].

With empty bucket, go down or up the slope with the heavy end toward the top of the slope [C] & [D].

Going Down Slope

C

AVOID INJURY OR DEATH

B–6612

WITH BUCKET FULL

• Keep the lift arms as low as possible.

• Do not travel or turn with the lift arms up.

• Turn on level ground.

• Go up and down slopes, not across them.

• Keep the heavy end of the machine uphill.

• Do not overload the machine.

Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

W–2018–1187

Going Down Slope

Raise the bucket only high enough to avoid obstructions on rough ground.

D

WITH BUCKET FULL

Going Up Slope –16–

B–6611

B–13297

543 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURE (Cont’d)

A

Filling The Bucket Push down on the top of the lift pedal until the lift arms are all the way down. Push the top of the tilt pedal to put the cutting edge of the bucket on the ground [A]

B–7379

B–6719

Drive slowly forward into the material. Push the bottom of the tilt pedal to raise the front of the bucket [B].

B

B–7379

Load, unload and turn on flat level ground. Do not exceed rated operating capacity shown on sign (decal) in cab. Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

W–2056–1187

Drive backward away from the material.

Emptying The Bucket Push down on the bottom of the lift pedal to raise the bucket over the truck box or bin [C].

B–6718

Drive forward slowly until the bucket is over the top of the truck box or bin. Push the top of the tilt pedal until the bucket is empty [C]. If all the material is near the side of the truck or bin, push it to the other side with the bucket.

C

B–7379

Never dump over an obstruction, such as a post, that can enter the operator cab. The machine could tip forward and cause injury or death.

W–2057–0694

B–6708

–17–

543 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES (Cont’d)

A

Digging Into The Ground Put the lift arms all the way down. Push the top of the tilt pedal until the cutting edge of the bucket is on the ground.

Drive forward slowly and continue to tilt the bucket down until it enters the ground [A].

B–7379

Push the bottom of the tilt pedal a small amount to increase traction and keep an even digging depth [B].

B–6720

B

Continue to drive forward until the bucket is full. When the ground is hard, raise and lower the cutting edge of the bucket with the tilt pedal while driving forward slowly.

B–7379

Push the bottom of the tilt pedal to tilt the bucket backward as far as it will go when the bucket is full [C].

B–6721

C

B–7379

B–6717

–18–

543 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURES (Cont’d)

A

Leveling The Ground (Using Lift Arms In Float Position) Push the top (toe) of the lift pedal all the way forward until the pedal is in the locked position (detent) to put the lift arms in a ‘‘float’’ position [A].

B–7379

Push the tilt pedal to change the position of the cutting edge on the bucket. With the bucket tilted farther forward, there is more force on the cutting edge and more loose material can be moved.

Never drive forward when the hydraulic control for lift arms is in float position.

B–6722

I–2005–1285

B

Drive backward to level loose material. Push the bottom of the lift pedal to unlock from the ‘‘detent’’ position.

Backfilling Lower the lift arms and put the cutting edge of the bucket on the ground.

B–7379

Drive forward to the edge of the hole to push the material into the hole [B].

Tilt the bucket forward as soon as it is past the edge of the hole [B].

If necessary, raise the lift arms to empty the bucket.

B–6724

–19–

543 Bobcat Loader Operation & Maintenance Manual

PARKING THE BOBCAT LOADER

A

1. Stop the Bobcat loader on level ground.

2. Lower the lift arms fully and put the edge of the bucket on the ground.

3. Pull the throttle all the way backward. Turn the key switch to the ‘‘OFF’’ position.

AVOID INJURY OR DEATH Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

B–2668

B

W–2045–1086

4. Engage the parking brake.

5. Lift the seat bar and make sure the foot pedals are in the locked position.

6. Unbuckle the seat belt. Remove the key from the switch to prevent operation of the loader by unauthorized personnel.

TRANSPORTING THE BOBCAT LOADER C–2563

C–7384

Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

W–2058–0494

A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [A].

Use the following procedure to fasten the Bobcat loader to the transport vehicle to prevent the loader from moving during sudden stops or when going up and down slopes [B].

B–7383

Lower the bucket or attachment to the floor. Stop the engine.Engage the parking brake. Install chains at the front and rear of the loader as shown in figure [B].

–20–

543 Bobcat Loader Operation & Maintenance Manual

LIFTING THE LOADER

A 1

AVOID INJURY OR DEATH • Before lifting, check fasteners on single point lift and operator cab.

• Assemble front cab fasteners as shown in this manual.

• Never allow riders in the cab or bystanders

within 15 feet (5 meters) while lifting the machine.

W–2007–0497

The loader can be lifted with the single point lift which is available as a kit from your Bobcat loader dealer.

Fasten the pins (Item 1) in the kit as shown in figure [A].

1

The single point lift, supplied by Melroe Company is designed to safely lift and support the Bobcat loader.

TOWING THE LOADER

B–7489

Never attempt to start the engine by pushing or pulling. Hydrostatic pumps and motors will be damaged.

I–2001–1285

If the engine will not start or the hydrostatic system is not working correctly, the loader can be pulled only when a towing tool is installed. The towing tool is available from your Bobcat loader dealer.

Do not push or pull the machine at more than 2 MPH (3,2 km/h) or for a distance of more than 25 feet (7,6 meters) with the towing tool in place.

I–2017–0389

–21–

543 Bobcat Loader Operation & Maintenance Manual

543Operation&MaintenanceManual#6722584–OperatingInstructionsSection

–22–

543 Bobcat Loader Operation & Maintenance Manual

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 ALTERNATOR BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Removing Coolant From The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . 37 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Battery Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

PREVENTIVE MAINTENANCE

FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . 46 Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Replacement Of The Hydraulic/Hydrostatic Filter Element . . . . . . . . . . . . . 43 Removing The Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 To Engage Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 To Disengage Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 LUBRICATION OF THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . 47 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 PARKING BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SEAT BAR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 U–JOINTS LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

–23–

543 Bobcat Loader Operation & Maintenance Manual

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

CORRECT

CORRECT

CORRECT

B–10731

B–12365

B–7469

Never service the Bobcat® Skid Steer Loader without instructions.

Use the correct procedure to lift or lower operator cab with lift arms down.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B–11799

B–3724

B–6593

Have good ventilation when welding or grinding painted parts.

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

Vent exhaust to outside when engine must be run for service.

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

Never work on loader 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 Melroe Company.

WRONG

WRONG

WRONG

B–6590

B–6580

B–6589

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 can penetrate the skin or eyes.

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

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

Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed 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.

–24–

MSW01–0698

543 Bobcat Loader Operation & Maintenance Manual

SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader.

Instructions are necessary before operating or servicing machine.

Read Operation & Maintenance Manual, Handbook and signs (decals) on machine. ollow 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

ITEM Engine Oil Engine Air Cleaner

Engine Cooling System Tires Seat Belt and Seat Bar Safety Signs & Safety Tread Indicator & Lights (Opt.) Operator Cab Lift Arm and Bob–Tach Pivot Pin Engine Fuel Filter Battery Hydraulic Fluid, Tubelines & Hoses Control Pedals & Steering

SERVICE REQUIRED

8–10

50

100

250

500 1000

Check the oil level and add oil as needed.

Replace the outer filter element only when the red ring shows in the indicator window. Check for leaks and damaged components Clean debris from shrouds and grills. Check coolant level in the recovery tank and add as needed.

Check for damaged tires and correct air pressure.

Check the condition of seat belt. Check the seat bar for correct operation .

Check for damage signs (decals) and safety treads Replace as needed.

Check for correct operation of all indicators & lights.

Check the fastening bolts, washer & nuts. Check the condition of cab.

Add grease to the fittings until the extra grease shows.

Remove water from filter.

Check cables & water level.

Check fluid level & add as needed. Check for damage, leaks & repair or replace as needed.

Check for correct operation. Make repairs or adjustments as needed.

Wheel Nuts L Check for loose wheel nuts & tighten as necessary.

Parking Brake Check operation. Adjust as needed.

Alternator Belt Check tension and adjust as needed.

Engine Oil & Filter Replace oil & filter.

Spark Arrestor Muffler Clean the spark chamber.

Seat Bar Grease pivot as needed.

Steering Shaft Pivots Grease two fittings. Add oil to steering shaft.

Hydraulic/Hydrostatic Filter • Replace the filter element.

U–Joint Grease three (3) fittings with correct grease.

Final Drive Trans.

Check fluid level and add as needed.

(Chaincase) Fuel Filter Replace the filter element.

Hyd./Hydro. Reservoir Replace the reservoir breather cap.

Chaincase Replace the fluid.

Hyd. Reservoir Replace the fluid.

L Check wheel nut torque every 8 hours for the first 24 hours.

• Also replace hydraulic/hydrostatic filter element when the transmission warning light comes stays on for five minutes after the fluid is at operating temperature.

J Or every 12 months.

–25–

543 Bobcat Loader Operation & Maintenance Manual

LIFT ARM SUPPORT DEVICE

A

NOTE: Lift arm support device is available from your dealer.

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

P–1715

Most maintenance and service work can be done with lift arms lowered.

Place jackstands under the rear corners of the loader.

One person must be in the operator’s seat, with the seat belt fastened and seat bar lowered, until the lift arm support device is installed [A].

Both sets of fasteners at the front of the operator cab (ROPS) must be assembled as shown in this manual. Failure to secure ROPS correctly can cause injury or death.

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

Have the second person install the lift arm support device over the rod of one of the lift cylinders [A]. The lift arm support device must be tight against the cylinder rod.

Lower the lift arms until the support device is held between the lift arm and the lift cylinder.

W–2005–1189

Repeat the procedure used above to remove the lift arm support device from the loader.

–26–

543 Bobcat Loader Operation & Maintenance Manual

OPERATOR CAB

A

The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects. Check with your dealer if the operator cab has been damaged.

Nut Washer Bolt

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.

Plate Bushing Washer MC–1181

P–0150

B

W–2069–1285

Raising The Operator Cab Stop the loader on a level surface. Lower the lift arms. If the lift arms must be up while raising the operator cab, install the lift arm support device (Page 22).

P–0151

Before the cab or the lift arms are raised for service, jackstands must be put under the rear corners of the frame. Failure to use jackstands can allow the machine to tip backward causing injury or death.

P–0152

C

W–2014–0895

Loosen the nut (both sides) at the corner of the operator cab [A].

Remove the nut and plate (both sides) [B].

Remove the bolt and washer (both sides) [B].

Lift on the grab handle and bottom of the operator cab slowly until the cab latching mechanism engages and the cab is all the way up [C].

P–1717

Lowering The Operator Cab

D

Pull down on the bottom of the operator cab until it stops at the latching mechanism. Release the latching mechanism and pull the cab all the way down [D].

Install bolt and washer from underneath the fender.

Install the plate and nut [B].

Tighten the nuts to 40–50 ft.–lbs. (54–68 Nm) torque [A].

P–1763

–27–

543 Bobcat Loader Operation & Maintenance Manual

SEAT BAR SYSTEM

A

The seat bar system has a pivoting seat bar with arm rests and has spring loaded interlocks for the lift and tilt control pedals. The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat, also the interlocks require the operator to lower the seat bar in order to operate the foot pedal controls. When the seat bar is up, the lift and tilt pedals are locked when returned to neutral position.

Clean & Lubricate

P–0155

AVOID INJURY OR DEATH

B

The seat bar system must lock the lift and tilt control pedals in neutral when the seat bar is up. Service the system if pedals do not lock correctly.

W–2105–1285

Sear Bar Inspection Clean

Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Operate each foot pedal to check both the lift and tilt functions. Raise the lift arms until the bucket is about 2 feet (600 mm) off the ground.

Raise the seat bar. Try to move each foot pedal. Pedals must be firmly locked in neutral position. There must be no motion of the lift arms or tilt (bucket) when the pedals are pushed.

P–0156

Pull the seat bar down, lower the lift arms and place the bucket flat on the ground. Stop the engine. Raise the seat bar and operate the foot pedals to be sure that the pedals are firmly locked in the neutral position. Unbuckle the seat belt.

Seat Bar Maintenance Clean any debris or dirt from the moving parts [A] & [B].

Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm).

Use a general purpose grease to lubricate the seat bar pivot points on each side of the cab [A]. If the seat bar system does not function correctly, check for free movement of each linkage part. Check for excessive wear. Adjust pedal control linkage. Replace parts that are worn or damaged. Use only genuine Melroe replacement parts.

–28–

543 Bobcat Loader Operation & Maintenance Manual

REAR DOOR

A

AVOID INJURY OR DEATH Never service or adjust the machine when the engine is running unless instructed to do so in the manual.

W–2012–0497 P–1764

Open the rear door to service the engine. Pull the door latch up and turn to the left to release the door latch [A].

Pull the rear door open.

B

Keep the rear door closed when operating the machine. Failure to do so could seriously injure a bystander.

W–2020–1285

1

3 P–0159

Adjustment Loosen the set screw (Item 1) [B].

2 P–0160

C

Loosen the nut (Item 2) [B].

Turn the bolt (Item 3) [B] in or out, until the door makes contact with both the top and bottom of the loader frame (Item 1) [C] when the door lever is in the latched position.

NOTE: It takes approximately 50 lbs. (223 N) of force to push the lever down when the latch is adjusted correctly.

1

With the set screw up, the flanges at the bolt must be to the side so that the set screw aligns with the flat surface at the end of the bolt.

P–1765

Tighten the set screw (Item 1) [B].

Tighten the nut (Item 2) to 65–70 ft.–lbs. (88–95 Nm) torque [B].

–29–

543 Bobcat Loader Operation & Maintenance Manual

REAR GRILL

A

To remove the rear grill, remove the four grill mounting bolts (Item 1) from the rear grill [A].

1 1 P–1673

B

Lift the rear grill up and remove from the loader [B].

P–1676

–30–

543 Bobcat Loader Operation & Maintenance Manual

AIR CLEANER SERVICE

A

See the Service Schedule (Page 21) for the interval to service the air cleaner system.

Check the air intake hose for damage. Check the air cleaner housing for damage. Check to make sure all connections are tight.

P–1688

Replace the large (outer) filter element only when the red ring shows in the window of the condition indicator (Item 1) [A].

1

NOTE: Push the button on the condition indicator (See Inset) and start the engine. If the red ring does not show, do not replace the filter element [A].

P–1692

Service the air cleaner as follows: Loosen the clamp (Item 1) and remove the dust cover (Item 2) [B] .

B

1 2 P–1694

Remove the dust cap from the cover [C].

C

P–1695

Remove the wing nut and remove the large air filter element [D].

D

NOTE: Make sure all sealing surfaces are free of dirt and debris.

Install the new filter element and tighten the wing nut.

Install the dust cover and tighten the wing nut.

P–1696

–31–

543 Bobcat Loader Operation & Maintenance Manual

AIR CLEANER SERVICE (Cont’d)

A

Only replace the inner filter element under the following conditions [A].

1. Replace the inner filter element every third time the outer filter is replaced.

2. Replace the inner filter element when the red ring still shows in the condition indicator window after the outer filter is replaced.

P–1693

Record the operating hours of the loader on the decal (Item 1) inside the rear door [B] .

B 1

P–1683

–32–

543 Bobcat Loader Operation & Maintenance Manual

FUEL SYSTEM

A

Fuel Specifications Use only clean, high quality fuel. Use Grade No. 2 fuel above 40F. (4C.). Use Grade No. 1 fuel at temperatures below 40F. (4C.).

Filling the Fuel Tank

P–1709

Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can cause an explosion or fire.

B

W–2063–0887

WRONG

Remove the fuel fill cap [A].

Use a clean, approved safety container to add fuel of the correct specifications. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING [B].

Install and tighten the fuel fill cap [A].

Fuel Filter

B–6586

C

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285

See the Service Schedule (Page 21) for the service interval when to remove the water from the fuel filter.

Turn the fuel shut–off valve clockwise to shut–off the fuel supply [C].

Loosen the drain at the bottom of the filter element (Item 1) to drain the water from the filter [D].

P–0194

Open the shut–off valve [C].

D

See the Service Schedule (Page 21) for the service interval when to replace the fuel filter.

Clean the area around the fuel filter. Close the shut–off valve [C].

Use a wrench to loosen the fuel filter bolt (Item 2) [D].

2

Remove the water trap and fuel filter (Item 1) [D].

Replace the seals as needed.

Install the new filter element and water trap.

1

Tighten the fuel filter bolt.

Open the shut–off valve [C]

P–1699

–33–

543 Bobcat Loader Operation & Maintenance Manual

FUEL SYSTEM (Cont’d)

A

Removing Air From The Fuel System After replacing the fuel filter element or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine.

1

Open the rear door. The engine must be cool.

Open the vent plug (Item 1) [A].

P–1699

Operate the hand pump (Item 1) until fuel flows from the vent plug with no air bubbles [B].

B

1

Tighten the vent plug.

Operate the hand pump until it feels solid [B].

P–1698

C

Move the engine speed control to minimum RPM. Open the valve (Item 1) and squeeze the hand pump several times [C].

1

Start the engine. When the engine runs smoothly, close the valve (Item 1) [C].

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

P–1690

W–2103–1285

–34–

543 Bobcat Loader Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM

A

Check the oil level every day.

Stop the engine and remove the dipstick [A].

Keep the oil level between the marks on the dipstick.

Use a good quality motor oil that meets API Service Classification of CC, CD or CE (See Oil Chart).

Replacing Oil And Filter See the Service Schedule (Page 21) for the service interval for replacing the engine oil and filter.

P–1685

Use the following procedure to replace the oil and filter: 1. Run the engine until it is at operating temperature.

Stop the engine.

B

2. Open the rear door and remove the cap from the end of the hose and drain the oil into a container [B].

3. Remove the filter (Item 1) [C].

4. Clean the filter housing surface. Put clean oil on the gasket of the new filter install the filter and tighten hand tight.

5. Remove the oil filler cap [D].

Use a good quality motor oil that meets API Service Classification of CC, CD or CE (See Oil Chart).

P–1686

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR ENGINE CRANKCASE)

C

1

P–1682

D

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL: USE API CLASSIFICATION CC, CD or CE) 6. Fill to capacity (See Specification Section, Page 58).

7. Start the engine and let it run for about 5 minutes.

Check for leaks at the filter. Check the oil level. Add oil until the level is at the ‘‘FULL’’ mark on the dipstick. Install the oil filler cap [D].

NOTE: DO NOT overfill the crankcase.

P–1689

–35–

543 Bobcat Loader Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM (Cont’d)

A

8. Record the operating hours of the loader on the decal inside the rear door [A].

P–1683

–36–

543 Bobcat Loader Operation & Maintenance Manual

COOLING SYSTEM

A

Check the cooling system every day to prevent overheating, loss of performance or engine damage.

Checking the Coolant Level Open the rear door.

The coolant recovery tank (Item 1) must be at the ‘‘FULL COLD’’ mark when engine is cool [A].

Add pre–mixed coolant, 50 water and 50 anti–freeze to the recovery tank if the coolant level is low.

P–1687

B Wear safety glasses to prevent eye injury when any of the following conditions exist: • When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

W–2019–1285

Cleaning The Cooling System Open the rear door.

P–1677

Remove the access panels at the blower housing [B].

C

Remove the rear grill (See Page 26).

Use air pressure or water pressure to remove the debris in the area of the radiator and oil cooler [C].

If debris is a problem, check with your dealer about the special debris screens.

P–1675

Removing Coolant From The Cooling System

D

Remove the rear grill (See Page 26). Remove the radiator cap [D].

P–1678

–37–

543 Bobcat Loader Operation & Maintenance Manual

COOLING SYSTEM (Cont’d)

A

Connect a hose to the coolant drain valve (Item 1) or use a funnel to keep coolant from getting into the engine compartment. Open the valve and drain coolant into a container [A].

When all the coolant is removed close the valve.

Fill the radiator with premixed coolant and install the radiator cap.

1

P–1697

Fill the coolant recovery tank 1/3 full with premixed coolant [B].

B

Check the radiator cap for correct pressure rating or overheating can result.

Check for leaks in the cooling system. Check for worn or damaged hoses, clamps or radiator. Check for loose or worn water pump belt.

Replace damaged parts immediately to prevent leaks and overheating Install the rear grill.

P–1687

–38–

543 Bobcat Loader Operation & Maintenance Manual

ALTERNATOR BELT ADJUSTMENT

A

Stop the engine.

Remove the engine belt shield.

Loosen the mounting bolt (Item 1) and adjustment bolt (Item 2) [A]. Move the alternator to set the belt tension at 5/16’’ (8 mm) movement between pulleys with 15 pounds (67 N) of force. Tighten the adjustment bolt and mounting bolt.

2

1 P–1701

–39–

543 Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM

A

Description The loader has a 12 volt, negative ground alternator charging system.

If the two fuses in the dash panel become damaged, replace them with the same type and size fuses.

Electrical System Service The battery cables must be clean and tight. Remove any acid or corrosion from the battery and cables with a baking soda and water solution. Cover the terminals of the battery with Melroe Battery Saver (P/N 886398) to prevent corrosion [A].

P–0742

Install the terminal covers.

Using A Booster Battery (Jump Starting)

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

Damage to the alternator can occur if:

• Engine is operated with battery cables

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.

disconnected.

• Battery cables are connected when using a fast charger or when welding on the loader.

(Remove both cables from the battery.)

• Extra battery cables (booster cables) are connected wrong.

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

W–2065–1296

I–2023–1285

Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame.

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

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.

The ignition must be in the ‘‘OFF’’ position.

The battery must be 12 volt.

Connect the end of the first cable to the positive terminal (+) of the booster battery. Connect the other end of the same cable to the loader battery positive (+) terminal [B].

Battery gas can explode and cause serious injury.

W–2066–1296

Connect the end of the second cable to the negative terminal (–) of the booster battery. Connect the other end of second cable to the engine [B].

B

Keep the cables away from moving parts.

Start the engine.

After the engine has started, remove the ground cable connected to the engine first.

Remove the cable connected to the loader battery.

P–1700

–40–

543 Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Battery Removal And Installation

Batteries contain acid which burns eyes and skin on contact. Wear 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.

P–1674

B

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

1

W–2065–1296

Open the rear door. Disconnect the negative (–) battery cable first [A].

Disconnect the positive (+) battery cable (Item 1) [A].

Remove the battery holddown clamp (Item 1) [B].

P–1679

C

Remove the battery from the loader [C].

P–1680

D

Always clean the terminals and cable ends when installing a new battery [D].

When installing the battery in the loader, do not touch any metal parts with the battery terminal posts.

Connect and tighten the battery cables. Connect the negative (–) cable last to prevent sparks.

P–0746

–41–

P–0744

543 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM

A

The hydraulic and hydrostatic systems use the same hydraulic fluid reservoir.

1

The system has an engine driven gear pump that supplies fluid to the control valve, lift and tilt cylinders.

Fluid also goes from the control valve to the hydrostatic transmission pumps to provide charge pressure and cooling.

A–3 filter element is installed on the left side of the engine compartment. This filter is used to clean the fluid for the hydrostatic transmission.

P–0163

The location of the oil cooler is above the engine. The oil cooler is used for cooling the hydraulic fluid before it returns to the hydrostatic pump.

B

Checking And Adding Fluid Use only recommended fluid in the hydraulic/hydrostatic system (See Specifications, on Page 58 for the correct fluid).

To check the fluid in the reservoir, use the following procedure: Put the loader on a level surface. Lower the lift arms and lay the attachment flat on the ground. Stop the engine.

Hydraulic fluid must show in the sight glass (Item 1) [A].

P–0165

C

If the fluid is not seen in the sight glass, remove the filler cap from the reservoir [B].

Add fluid to the reservoir until it shows in the sight glass [C].

Replace the filler cap.

P–0166

–42–

543 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Replacement Of The Hydraulic/Hydrostatic Filter Element See the Service Schedule (Page 21) for the correct service interval.

Stop the engine. Open the rear door.

1

Clean the area around the filter housing.

Remove the filter element (Item 1) [A].

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

Lubricate the rubber gasket with grease.

P–1684

Install the filter element and hand tighten.

B

Operate the loader and check for leaks at the filter.

Check fluid level in the reservoir and add as needed.

Removing The Hydraulic Fluid See the Service Schedule (Page 21) for the service interval to replace the fluid. The fluid must also be replaced if it becomes contaminated and after any major repairs.

Remove the filler cap from the reservoir [B].

Remove the screen from the fill pipe [C].

Remove fluid from the hydraulic reservoir.

P–0165

Wash the screen in clean solvent. Install the screen in the fill pipe.

C

Remove the filter element and install a new filter element.

Add hydraulic/hydrostatic fluid to the reservoir (See Specifications, Page 58 for the correct fluid). DO NOT fill above the sight glass.

Operate the loader. Stop the engine and check the fluid level. Add as needed.

P–0164

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285

–43–

543 Bobcat Loader Operation & Maintenance Manual

SPARK ARRESTOR MUFFLER

A

See the Service Schedule (Page 21) for correct service interval. Do not operate the loader with a defective exhaust system.

1

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

P–1681

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.

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles. Failure to obey can cause serious injury.

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

W–2011–1285

I–2022–0595

When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside.

Exhaust fumes contain odorless, invisible gases which can kill without warning.

Stop the engine. Open the rear door.

Remove the plug (Item 1) at the bottom of the muffler [A].

W–2050–1285

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

W–2068–1285

Start the engine.

Wearing safety goggles, have a second person hold a block of wood over the outlet of the muffler (with the engine running) for about 10 seconds.

Stop the engine and install the plug. Close the rear door.

–44–

543 Bobcat Loader Operation & Maintenance Manual

TIRE MAINTENANCE

A

Wheel Nuts See the Service Schedule (Page 21) for the service interval to check the wheel nuts. The correct torque is 105–115 ft.–lbs. (142–156 Nm) [A].

Tire Rotation Check the tires regularly for wear, damage and pressure (See Specifications, Page 58 for the correct tire pressure).

Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to the rear and rear tires to the front [B].

CD–06337

It is important to keep the same size tires on each side of the loader to avoid excessive wear. If different sizes are used, each tire will be turning at a different speed and cause excessive wear. The tread bars of all the tires must face the same direction.

B

Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for the correct pressure before operating the loader.

Tire Inflation Tires are to be repaired only by an authorized person using the proper procedures and safety equipment. Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage.

C–1965

The rim flange must be cleaned and free of rust. The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire, avoid excess pressure which can rupture the tire and cause serious injury or death. During inflation of the tire, check the tire pressure frequently to avoid over–inflation.

Do not inflate tires above specified pressure.

Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death.

W–2078–1285

–45–

543 Bobcat Loader Operation & Maintenance Manual

FINAL DRIVE TRANSMISSION (CHAINCASE)

A

Checking And Adding Oil The chaincase contains the final drive sprockets and chains and uses the same type of oil as the hydraulic/hydrostatic system (See Specifications Section, Page 58).

To check the chaincase oil level, use the following procedure:

1

Drive the loader onto a level surface. Stop the engine.

Remove the plug (Item 1) at the front of the chaincase housing [A]..

If oil can be reached with the tip of the your finger through

P–1714

the hole the oil level is correct.

If the level is low, add oil through the check plug hole until the oil flows from the hole. Install and tighten the plug.

–46–

543 Bobcat Loader Operation & Maintenance Manual

LUBRICATION OF THE BOBCAT LOADER

A

Lubricate the Bobcat loader as specified in the Service Schedule (Page 21) for the best performance of the loader.

Always use a good quality lithium based multi–purpose grease when you lubricate the loader. Apply the lubricant until the extra grease shows.

Lubricate the following locations on the loader:

1

1. Rod End Lift Cylinder (both sides) [A].

P–1708

2. Base End Lift Cylinder (both sides) [B].

B

2

P–1762

3. Lift Arm Pivot Pin (both sides) [C].

C 3

P–1691

4. Base End Tilt Cylinder [D].

D 4

P–1710

–47–

543 Bobcat Loader Operation & Maintenance Manual

LUBRICATION OF THE BOBCAT LOADER (Cont’d)

A

5. Rod End Tilt Cylinder [A].

6. Bob–Tach Pivot Pin (both sides) [A].

5 6

P–1713

7. 250 Hours: Steering Lever Shaft Bearings (2) [B] & [C]. .

B 7

P–1705

C 7

P–1711

–48–

543 Bobcat Loader Operation & Maintenance Manual

BOB–TACH

A

Check for free movement of wedges and Bob–Tach levers.

The wedges (Item 1) must extend far enough to engage the holes in the attachment [A].

1

Bob–Tach wedges must extend through the holes in attachment. Lever(s) must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death.

P–1723

B

W–2102–0497

Replace wedges that are bent or broken.

PARKING BRAKE PEDAL Adjustment Raise the operator cab (Page 23).

Turn the nuts to adjust the brake pedal [B].

There must be 3/4’’ (19 mm) of movement under the bottom edge (heel) of the brake pedal.

P–0199

PIVOT PINS

C

All lift arm and cylinder pivots have a large pin held in position with a retainer bolt and lock nut [C].

Check that the lock nuts are tightened to 18–20 ft.–lbs.

(24–27 Nm) torque.

P–0201

–49–

543 Bobcat Loader Operation & Maintenance Manual

AUXILIARY CONTROL LOCKBOLT

A

543Operation&MaintenanceManual#6722584–PreventiveMaintenanceSection

The auxiliary control has a lockbolt (Item 1) that must be removed to use the optional auxiliary hydraulics.

Raise the operator cab (See Page 23).

Remove the nut and (Item 1) bolt at the right hand steering lever [A]..

1

P–1716

U–JOINTS LUBRICATION See the Service Schedule (Page 21) for the service interval when to lubricate the U–joint grease fittings (Item 1) [B].

B

Raise the operator cab (See Page 23).

Use the special U–joint grease (P/N 6599719) to assure correct ubrication for the U–joint. [B].

1

P–1712

–50–

543 Bobcat Loader Operation & Maintenance Manual

TROUBLESHOOTING TROUBLESHOOTING THE DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 54 TROUBLESHOOTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 TROUBLESHOOTING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . 55

TROUBLE– SHOOTING

–51–

543 Bobcat Loader Operation & Maintenance Manual

–52–

543 Bobcat Loader Operation & Maintenance Manual

TROUBLESHOOTING The following information identifies loader problems which can occur most often. Service procedures for correcting loader problems can be found in this manual on the pages indicated. Some prodecures are marked ’D/S’ (Dealer Service) and must be performed only qualified Bobcat service personnel.

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

TROUBLESHOOTING THE ENGINE PROBLEM Engine won’t turn over with starter.

Engine turns with starter, but is difficult to start.

Engine has little power or runs

CAUSE

CORRECTION

PAGE

Battery has low charge.

Charge battery and find cause loss of damage.

–

Cables loose or dirty.

Clean and tighten the battery cables.

36

Damaged starter, solenoid or wiring.

Check the starting circuit.

Repair as needed.

D/S

Wrong starting procedure.

Use correct starting procedure.

9

Air in the fuel.

Remove air from the fuel system.

30

Ignition system is damaged.

Check & repair as needed

D/S

Engine stop control is pulled out.

Push engine stop control in

1

Auxiliary control lever is in ”detent”.

Take out of ”detent”.

5

No fuel in tank.

Add fuel.

29

Vent in fuel filler cap is plugged.

Clean the vent.

–

Dirt or water in fuel system.

Make repairs as needed.

D/S

Fuel filter is dirty.

Install anew filter.

29

Hole in fuel line.

Repair as neede.

–

Weak battery.

Charge or replace battery

–

Wrong oil in engine.

Change oil per specifications

31

Cylinder compression is low.

Reconditin the engine.,

D/S

Engine has overheated.

See Engine Cooling System.

33

Poor fuel quality.

Use fresh, good quality fuel.

29

Injectors are not working. correctly

Repair as needed.

D/S

Dirt, water or air in fuel system

Clean and repair as needed/

D/S

–53–

543 Bobcat Loader Operation & Maintenance Manual

TROUBLESHOOTING THE ENGINE (CONT’D) PROBLEM Engine has little power or runs rough.

Engine overheats.

CAUSE

CORRECTION

PAGE

Engine is hot.

See ”Engine Overheats”.

–

Restricted exhaust

Clean exhaust system

40

Dirty air cleaner.

Install new element.

27

Cylinder compression is low.

Recondition the engine.

D/S

Restrictrion in cooling air flow.

Check for debris on radiator grill.

33

Blower shroud damaged or missing.

Check shroud and repair or repplace as needed.

–

Engine is overheated.

Run at full throttle.

TROUBLESHOOTING THE DRIVE SYSTEM PROBLEM

CAUSE

No drive on both sides.

No drive on one side.

Loader pulls to one side.

CORRECTION

PAGE

Hydraulic fluid is low.

Check fluid level. Add as needed.

38

Damaged hydraulic pump.

Check condition of hydraulic pump & replace as needed.

D/S

Hydrostactic systme is damaged. Check hydrostatic system

D/S

Control linkage is disconnected.

Repair linkage.

D/S

Hydrostatic system is damged.

Check hydrostatic sysem and make repair as neede.

D/S

Wrong tire pressure.

Check all tires for correct pressure.

41 & 58

Steering linkage interference.

Check steering linkage and adjust as needed.

D/S

Hydrostatic system is damaged.

Check system. Repair as needed.

D/S

Loader moves when sterring levers are in neutral

Steering linkage out of adjustment. Adjust steering linkage.

D/S

System is overheating.

Hydraulic fluid level is low

Check fluid level and add as needed.

38

Cooling system is dirty. Air restricted

Clean cooling system. Check for debris on radiator grill.

33

Low charge pressure (transmission light on0.

Check by–pass valve.

D/S

Auxiliary control in ”detent’.

Take out of ”detent’.

46

Loader is oaverloaded.

Use correct size attachment.

D/S

Hydrostatic system is damaged

Check system and make repair

D/S

Out of adjustment.

Adjust parking brake.

45

Parking brake will not hold.

–54–

543 Bobcat Loader Operation & Maintenance Manual

TROUBLESHOOTING THE HYDRAULIC SYSTEM PROBLEM No hydraulic action.

CAUSE

CORRECTION

PAGE

No hdraulic fluid.

Check fluid level and add as needed.

38

Pedals are disconnected.

Check linkage. Repair as needed.

–

Relief valve is damaged.

Replace the relief valve.

D/S

Hydraulic pump is damaged.

Check pump. Replace as needed.

D/S

Hydraulic fluid is too thick.

Let machine warm up.

11

Hydraulic action is rough.

Hydraulic fluid level is low.

Check fluid level and add as needed.

38

Hydraulic action is slow.

Pedal is hitting floor or debris under pedal.

Check adjustment. Remove dirt.

–

Cylinders leak internally.

Check condition of cylinders and repair as needed.

D/S

Hydraulic pump is damaged.

Check pump. Replace as needed.

D/S

Control valve is damaged.

Check valve and repair as needed.

D/S

Hydraulic fluid is too thick.

Let machine warm up.

11

Damage to cylinder rods or seals.

Repair cylidners.

D/S

Hydraulic cylinders leak fluid.

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543Operation&MaintenanceManual#6722584–TroubleshootingSection

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543 Bobcat Loader Operation & Maintenance Manual

MACHINE SIGN TRANSLATIONS 8.

IMPORTANT (6560573) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 WARNING (6579511) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 SERVICE SCHEDULE (6567875) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 WARNING (6579510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 WARNING (6579528, 6577754, 6579639, 6579509) . . . . . . . . . . . . . . . . . . . 64

MACHINE SIGN TRANSLATIONS

MACHINE SIGNS (DECALS) Machine signs (decals) are an esential part of the loader. (See Page xii & xiii.) This section provides French and Spanish translations of the machine signs that are in English. The Operator’s Handbook is also available in a combination English, French, German, Spanish editions.

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543 Bobcat Loader Operation & Maintenance Manual

IMPORTANTE (SPANISH) ESTA MAQUINA ESTA EQUIPADA POR LA FABRICA CON UN AMORTIGUADOR DE CHISPAS DEL SILENCIADOR, APROBADO POR EL SERVICIO DE SILVICULTURA DEL U.S.D.A. (DEPARTMENTO DE AGRICULTURA DE LOS ESTADOS UNIDOS).

ES NECESARIO LIMPIAR ESTE AMORTIGUADOR DE CHISPAS DEL SILENCIADOR PARA MANTENERLO EN BUEN ESTADO. HAY QUE DARLE SERVICIO AL AMORTIGUADOR, VACIANDO LA CAMARA DE CHISPAS CADA 100 HORAS DE FUNCIONAMIENTO. SI ESTA MAQUINA ESTA DESTINADA PARA TRABAJAR EN BOSQUES, MATORRALES O EN PASTOS QUE PUEDAN INCENDIARSE, ENTONCES TIENE QUE ESTAR EQUIPADA CON UN AMORTIGUADOR DE CHISPAS EN EL SISTEMA DEL ESCAPE Y TIENE QUE MANTENERSE EN PERFECTAS CONDICIONES DE TRABAJO. ES NO HACER ESTO CONSTITUYE UNA INFRACCION DE LA LEY ESTATAL DE CALIFORNIA, SECCION 4442, PRC. REFIERASE A LAS LEYES Y REGULACIONES LOCALES EN CUANTO A LOS REQUISITOS DEL AMORTIGUADOR DE CHISPAS.

IMPORTANT (FRENCH) CETTE CHARGEUSE EST EQUIPPEE A LA SORTIE DE L’USINE D’UN SILENCIEUX PARA–ETINCELLES APPROUVE PAR LE SERVICE DES EAUX ET FORETS DES ETATS–UNIS. IL EST INDISPENSABLE D’EFFECTUER UN ENTRETIEN REGULIER DE CE PARE–ETINCELLES AFIN DE LE GARDER EN BON ETAT DE MARCHE. L’ENTRETIEN CONSISTE A VIDER LA CHAMBRE A ETINCELLES TOUTES LES 100 HEURES DE MARCHE. SI CET ENGIN EST UTILISE SUR UN TERRAIN COUVERT D’ARBRES, DE BROUSSAILLES, OU D’HERBAGES INFLAMMABLES, IL FAUT INSTALLER LE PARE–ETINCELLES ET LE GARDER EN BON ETAT DE MARCHE. CONSULTER LES APPLICABLES.

REGLEMENTATIONS

LOCALES

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543 Bobcat Loader Operation & Maintenance Manual

ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTE

• Mantenga le puerta cerrada excepto para dar servicio.

• Mantenga el motor limpio y que no tenga material inflamable.

• Mantenga el cuerpo. objetos sueltos y la ropa lejos de los conductores eléctricos, piezas móviles, piezas calientes y del escape.

• No use el cargador en lugares donde

hay polvo o gases explosivos o materiales inflamables cerca al escape.

• Todos los gases del escape pueden

matar. Ventile siempre el lugar de trabajo.

• No use nunca éter o líquido del arranque en los motores

• Les liquides sous pression peuvent pénétrer au travers de

• Escapes de líquido bajo presión pueden penetrat en la

• L’acide des batteries provoque de graves brûlures, porter

• El ácido de la batería puede causar quemaduras severas,

• Les batteries dégagent des gaz inflammables et

de diesel que tienen tapones encendedores. Use solamente las ayudas para el arranque que sean aprobados por el fabricante del motor.

piel y causar heridas graves. Se requiere atención médica inmediata. Use gafas. Use cartón para revisar si hay fugas. use gafas. Si el ácido hace contacto con los ojos, la piel o la ropa, lávelos bién con agua. Si el contactor fuel en los ojos, lávelo bién y vaya al médico.

• Las baterias producen gas inflammable y explosivo.

la peau et causer de graves blessures. Consulter immédiatement un médecin Porter des lunettes de sécurité. Utiliser du carton pour repérer les fuites. des lunettes de sécurité. S’il entre en contact avec les yeux, la peau ou les vêtements, rincer généreusement à l’eau. Pour les yeux, appeler un médecin.

explosifs. Tenir les arcs électriques les étincelles, les flammes et las cigarettes allumées à l’écart.

• En cas de démarrage par pontage, effectuer le dernier

Mantenga lejos, arcos, chispas, llamas y tabaco encendido.

branchement (Câble négatif) au moteur (jamais à la batterie). Pour débrancher, déconnecter d’abord le câble négatif du moteur.

• Para arranque con batería auxiliar, conecte de último el

• Ne jamais utiliser d’éther ou de liquide de démarrage sur

cable negativo al motor del cargador (nunca la batería).

Despues de hacer el arranque con cables, quite peimero la conección negativa del motor.

un moteur diesel avec des bougies de préchauffage.

N’employer que les aides au démarrage approuvées par le fabricant.

AVERTISSEMENT (FRENCH) EVITER LES BLESSURES, VOIRE LA MORT

• Maintenir la porte arrière fermée, sauf pour les entretiens.

• Débarasser le moteur de toute matière inflammable.

• Maintenir le corps, les objets non attachés et les vêtements à l’écart des contacts électriques, des pièces mobiles et brûlantes et de l’échappement.

• Ne pas utiliser la machine dans un endroit chargé de poussières ou de gaz explosifs, et où l’échappement risque de toucher des matériaux inflammables.

• Les gaz d’échappement peuvent être mortels. Toujours aérer.

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543 Bobcat Loader Operation & Maintenance Manual

9. Cinturon/barra del asiento y enclavamientos de los pedales

PROGRAMA DE SERVICIO (SPANISH) CADA 10 HORAS 1. Aceite del Motor–Verifique el nivel–no lo llene demasiado (Consulte el Manual del Operario para ver cual fluido recominenda).

2. Filtro del Aire del Motor–(Vacie la tapa recolectora de polvo y cambie el elemento si es necesario).

3. Sistema de Enfriamiento del Motor–Limpiar la basura de las aletas de enfriamiento de la guardera y del enrejado. Verifique en frio el nivel del líquido enfriador, agregue etilenglicol y agua en las cantidades necesarias para obtener una proporción de 50% a 50% de cada uno.

4. Verifique las correas del ventilador y de la bomba para asegurase qu están en buenas condiciones y que la tensión está bién.

5. Brazos de Elecación y Puntos de Pivote del Cilindro – Lubríquelos con grasa de base be litio para uso multiple.

6. Neumáticos – Verifique la persión de aire.

FLOTATION – 35 PSI (241 kPa) STANDARD Y CLASIFICACION DE 8 PLIEGOS – 50 PSI (340 kPa), 5.70 x 12 – 40 PSI (275 kPa). Verifique que no tengan cortadas.

7. Sistema de Aire del Motor – Verifique que no haya escapes ni componentes dañados.

8. En General – Verifique que no haya piezas ni sueltas ni rotas, qu no estén dañados ni el cinturón de seguridad ni la cabina del operador. Verifique tembién el funcionamiento de los instrumentos, que no haya tuercas sueltas en las quedas, escapes de aceite, etc.

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– Comprobar su funcionaminento. Reparar o cambiar si es necessario. Eliminar la suciedad en las piezas moviles.

10. Filtro del Combustible – Purgue el agua atrapada (solamente para diesel).

CADA 50 HORAS 1. Fluido Hidráulico – Verifique el nivel del fluído.

Consulte el Manual del Operador para ver vual fluído recomendado.

2. Caja de la Cadena – Verifique el nivel del fluído.

Consulte el Manual del Operador para ver cual fluído recomendado.

3. Batería – Verifique su condición.

4. Controles y Frenos – Verifique el funcionamiento.

Hacer ajustes si es necesario.

CADA 100 HORAS 1. Sistema de Encendido – Verificar las bujias, los platinos y la sincronización–cambie las piezas defectuosas (solamente para gasolina).

2. Silenciador con Amortiguador de Chispas – Vasie la cámara de chispas.

3. Sistema Hidráulico – Cambie el filtro – modelos 440, 540.

4. Aceite del Motor – Drenarlo mientras está caliente y cambiar el filtro (en las cargadoras 440 solamente se cambia el aceite cada 25 horas). consulte el Manual del Operador para ver cual fluído recomendado.

CADA 250 HORAS 1. Sistema Hydraulico – Cambie el filtro en el model 843.

2. Filtro Final del Combustible – Reemplace el elemento del filtro.

543 Bobcat Loader Operation & Maintenance Manual

3. Linea Motriz – Engrase la uniones universales con una grasa aprobada según la recomendación del Manual de Servicio.

4. Engrase el pivote de la barra del asiento en cuanto sea necesario.

5. Cojinetes de la dirección – Lubricar con grasa al litio de uso general.

6. Aplicar aceite o grasa al árbol.

7. Filtro hidrostático (sólo máquinas 640, 740 y 843) – Sustituir el elemento filtrante. Sustituirlo también si el piloto de aviso de la transmisión del salpicardero está encendido y permanece así durante cinco (5) minutos después de que el líquido hidrostático haya alcanzado la temperatura de trabajo.

CADA 500 HORAS 1. Sistema Hidráulico – Cambie el filtro de brone si está equipado con este.

2. Filtro Primario del Combustible – Limpie el cubo de sedimento.

3. Reemplace la tapa del respiradero del depósito hidráulico.

CADA 1000 HORAS 1. Depósito Hidráulico–Drenar el fluído y reemplazarlo.

Consulte el Manual del Operador para ver cual fluído recomendados.

2. Caja de la Cadena–Drene el fluído y reemplazarlo.

Consulte el Manual del Operador para ver cual fluído recomendado.

PROGRAMME D’ENTRETIEN (FRENCH) TOUTES LES 10 HEURES 1. Huile de moteur–Vérifier le niveau – ne pas remplir à rasbord (conseiller le manuel d’utilisation pour le fluide recommandé).

2. Filtre à air du moteur (vider la capsule à poussiere changer l’élément si nécessaire).

3. Système de refroidissement du moteur – nettoyer les débris de ailettes de refroidissement, coucliers et grilles. – Vérifier le niveau de température de liquide de refroidissement, ajouter 50–50 d’éthylène glycol et eau autant que nécessaire.

4. Vérifier la condition et la tension du ventilateur et des courroies de transmission de la pompe.

5. Levier du chargeur et les points de pivot du cylindre – graisser avec une huile multi–usage à base de lithium.

6. Pneus – vérifier le gonflement: FLOTATION – 35 PSI (241 kPa), STANDARD et 8 PLY – 50 PSI (340 kPa), 5.70 x 12 – 40 PSI (275 kPa); vérifier l’état des pneus (entailles).

7. Système d’aération du moteur – contrôler les fuites et les éléments abimés.

8. Conseils géneraus: vérifier les pièces abimées ou ayant du jeu, centinure de sécurité abimée et cabine de l’utilisateur, instrument de commande, écrous devissés des roues, fuites d’huile, etc.

9. Ceinture de sécurité/arceau de siège et verrouillage des

TOUTES LES 100 HEURES 1. Système d’allumage – vérifier les bougies régler l’allumage, remplaer les pièces défectueuses (essence seulement).

2. Pot d’echappement – vider la chambre à étincelles.

3. Système hydraulique – changer le filtre (des modèles 440 et 540).

4. Huile de moteur – vider chaud et changer le filtre (huile de remplacement seulement, toutes les 25 heures pour chargeur 440). Voir le manual d’utilisation en ce qui concerne l’huile recommendée.

TOUTES LES 250 HEURES 1. Système hydraulique – changer le filtre sur le 843.

2. Dernier filtre à essence – remplacer la pièce du filtre.

3. Arber de transmission – graisser le joint U avec un lubrifiant approivé par le manuel.

4. Graisser le pivot du siège autant que nécesaire.

5. Bagues de direction – lubrifier avec une graisse tous usages à base de lithium.

6. Levier de direction – ajouter de l’huile ou de la graisse à l’arbre.

7. Filtre hydrostatique – séries 640, 740 et 843 uniquement) – remplacer l’élément de filtre.

Remplacez–le aussi si le témoin de transmission au tableau de bord s’allume et reste allumé pendant cinq (5) minutes après que l’huile hydrostatique ait atteint sa température de fonctionnement.

TOUTES LES 500 HEURES 1. Système hydraulique – remplacer le filtre bronze si le système en est équipé.

2. Premier filtre à essence – nettoyer le récipiente à seidments.

3. Remplacer le bouchon – filtre du réservoir hydraulique.

TOUTES LES 1000 HEURES 1. Réservoir hydraulique – vider le fluide et le remplacer.

Voir manuel d’utilisation pour le fluide recommendé.

2. Boîte à chaînes – vider le fluide et le remplacer par celui conseillé par le manual d’utilisation.

pédales – Vérifiez le fonctionnement. Remplacez ou réparez si nécessaire. Eliminez les saletés et les débris de pièces mobiles.

10. Filtre du carburante – retirer l’eau qui s’y trouve (diesel seulement).

TOUTES LES 50 HEURES 1. Fluide hydraulique – vérifier le niveau du fluide. Voir le manuel d’utilisation pour le fluide recommendé.

2. Boíte à chaines – vérifier le niveau du fluide.

Consulter le manuel d’utilisation en ce qui concerne le fluide recommendé.

3. Batterie – vérifier l’etat.

4. Commandes et freins – vérifier l’etat de marche, régler si nécessaire.

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543 Bobcat Loader Operation & Maintenance Manual

Solamente con control de piso

Commande au pied seulement

ADVERTENCIA (SPANISH)

ATTENTION (FRENCH)

EVITE HERIDAS O LA MUERTE

EVITER LES BLESSURES OU LA MORT

NO USE NUNCA EL CARGADOR SIN LEER LAS INSTRUCCIONES. LEA EL MANUAL DEL OPERATIO, EL MANUAL DE SERVICIO Y LA GIA DEL OPERARIO.

NE JAMAIS SE SERVIR DE LA CHARGEUSE SANS INSTRUCTIONS. LIRE LE MANUEL DE L’OPERATEUR EL D’ENTRETIEN AINSI QUE LE GUIDE D’UTILISATION.

NO VIAJE O DE LA VUELTA CON LOS BRAZOS DE ELEVACION ARRIBA. CARGUE, DESCARGUE Y DE LA VUELTA ESTANDO EN UN SITIO PLANO Y NIVELADO. NO EXCEDA LA CAPACIDAD NOMINAL DE FUNCIONAMIENTO (VEA EL AVISO EN EL CARGADOR).

NE PAS SE DEPLACER NI VIRER AVEC LE BRAS RELEVES. CHARGER, DECHARGER ET VIRER SUR UN SOL PLAT ET HORIZONTAL. NE PAS DEPASSER LE CAPACITE NOMINALE (CONSULTER L’AUTOCOLLANT APPOSE SUR LA CARGEUSE).

USE LA BARRA DEL ASIENTO. ASEGURESE BIEN EL CINTURON DE SEGURIDAD.

UTILISER L’ARCEAU DE SECURITE. ATTACHER SOIGNEUSEMENT LA CEINTURE DE SECURITE.

NUNCA MODIFIQUE EL EQUIPO NI USE ADITAMENTOS QUE NO ESTEN APROBADOS POR LA COMPAÑIA MELROE.

NE JAMAIS MODIFIER L’EQUIPEMENT NI SE SERVIR D’ACCESSOIRES QUE NE SONT PAS APPROUVES PAR MELROE COMPANY.

MANTENGA LOS PIES EN LOS PEDALES. MAINTENIR LES PIEDS SUR LES PEDALES. EN LA PENDIENTES, MANTENGA EL EXTREMO PESADO DE CARGADOR EN POSICION ASCENDENTE.

DANS LES PENTES, TOUJOURS MAINTENIR LA PARTIE LA PLUS LOURDE DE LA CHARGEUSE VERS LE HAUT.

ANTES DE BAJARSE DEL CARGADOR POUR QUITTER LA CHARGEUSE: 1. BAJE LOS BRAZOS DE ELEVACION. COLOQUE EL ADITAMENTO BEIN EN EL SUELO. 2. PARE EL MOTOR.

1. ABAISSER LES BRAS DE LEVAGE. POSER L’EQUIPEMENT A PLATE SUR LE SOL. 2. ARRETER LE MOTEUR.

3. PONGA EL FRENO.

3. ENCLENCHER LE FREIN DE STATIONNEMENT.

4. LEVANTE LA BARRA DEL ASIENTO. MUEVA LOS PEDALES HASTA QUE AMBOS SE TRABEN.

4. RELEVER L’ARCEAU DE SECURITE. DEPLACER LES PEDALES JUSQU’A CE QU’ELLES SOIENTE TOUTES DEUX VERROILLEES.

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543Operation&MaintenanceManual#6722584–MachineSignsTranslationsSection

ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTE LLEVE LA CARGA EN POSICION BAJA

PELIGRO (SPANISH)

EL NO OBEDECER ESTA ADVERTENCIA PUEDE CAUSAR LADEAMIENTO O VUELCOS O PERDIDAD DE LA CARGA Y DE LA VISIBILIDAD.

EVITE LA MUERTE

• MANTENGASE RETIRADO DE ESTA AREA CUANDO

AVERTISSEMENT (FRENCH)

LOS BRAZOS DE ELEVACION ESTAN ELEVADOS, A MENOS QUE ESTEN TRABADOS POW EL TOPE. • EL MOVER EL PIE DEL PEDAL O FALLA DE UNA PIEZA PUEDEN CAUSAR LA CAIDA DE LOS BRAZOS DE ELEVACION.

EVITER DES BLESSURES OU LA MORT TENIR LA CHARGE VERS LE BAS. LE NON RESPECT PEUT ENTRAINER UN BASCULEMENT OU UN RENVERSEMENT DE LA MACHINE, UNE PERTE DE LA CHARGE OU DE VISIBILITE.

DANGER (FRENCH) EVITER LA MORT

• EVITER CETTER ZONE LORSQUE LES BRAS DE LEVAGE RELEVÉS NE SONT PAS ASSURÉS PAR DES ARRETS DE BRAS DE LEVAGE. • UNE PEDALE ACTIONNÉE OU UNE PICE DEFECTUEUSE. PEUT PROVOQUER L’ABAISSEMENT DES BRAS DE LEVAGE.

ADVERTENCIA (SPANISH) EL CILINDRO CONTIENE GAS BAJO ALTA PRESION. EL ABNRIR EL CILINDRO PUEDE SOLTAR LA VARILLA Y CAUSAR HERIDAS O LA MUERTE.

AVERTISSEMENT (FRENCH) LES VERINS RENFERMENT UN GAZ SOUS PRESSION. NE JAMAIS OUVRIR UN VERIN CAR LA TIGE RISQUE DE S’ECHAPPER BRUTALEMENT ET DE CAUSER DES BLESSURES OU MEME LA MORT.

PELIGRO (SPANISH) EVITE LA MUERTE

• EL FORZAR EL IMPLEMENTO CONTRA EL SUELO

HACE QUE LA RUEDDAS DELANTERAS SE ELEVEN.

• NUNCA SE META DEBAJO NI ALCANCE NADA DEBA-

JO DE LOS BRAZOS DE ELEVACION O DEL CILINDRO DE ELEVACION SIN QUE ESTE INSLADO UN TOPE APROBADO EN LOS BRAZOS DE ELEVACION.

DANGER (FRENCH) EVITER LA MORT

• L’ACCESSOIRE PEUT ETRE APPUYE CONTRE LE SOL ET SOULEVER LES ROUES AVANT.

• NE JAMAIS ALLER SOUS NI METTRE LES MAINS

SOUS LES BRAS OU LE VERIN DE LEVAGE SANS QU’UN ARRET DE BRAS DE LEVAGE APPROUVE SOIT INSTALLE.

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543 Bobcat Loader Operation & Maintenance Manual

SPECIFICATIONS LOADER DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 CAPACTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 OPERATION & PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

SPECIFICATIONS

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543 LOADER SPECIFICATIONS LOADER DIMENSIONS

• Dimensions are given for loader equipped with standard tires and dirt bucket.

Dimensions may vary with other types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

• Where applicable, specifications conform to SAE standards and are subject to change without notice.

B–12767

This loader was designed without counterweights or ballasts. Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts.

OPERATIONS & PERFORMANCE Weights Operating Weight . . . . . . . . . . . . . . . . . . .

Rated Operating Capcity . . . . . . . . . . . . .

Tipping Load . . . . . . . . . . . . . . . . . . . . . . .

3270 lbs. (1485 kg) 800 lbs. (363 kg) 1600 lbs. (726 kg)

Travel Speed . . . . . . . . . . . . . . . . . . . . . . . .

Infinitely variable 0–5.4 MPH (8,7 km/hr.)

Controls Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loader Function . . . . . . . . . . . . . . . . . . . .

Engine Main Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake . . . . . . . . . . . . . . . . . . . . . .

Direction & speed controlled by two hand levers.

Lift & Tilt Function: Controlled by separate foot pedals.

Front Auxiliary Function: Controlled by the right steering lever.

Hand lever throttle; pull cable shutdown; key–type starter switch; Hydrostatic Mechanical disc, foot operated pedal

ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Horsepower . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Governed RPM . . . . . . . . . . . .

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of Cylinders . . . . . . . . . . . . . . . . .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . .

Displacement . . . . . . . . . . . . . . . . . . . . . . .

Cooling System . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Ventilation . . . . . . . . . . . . . . . .

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kubota D950–B Diesel 21.5 HP (16 kW) 3000 RPM 42.5 ft.–lbs. (57,6 Nm) @ 1800 RPM Three 2.95/2.76(74,9/70,1) 56.6 cu. in. (928 cm ) Liquid Pressure System W/Filter External Dry replaceable paper cartridge with safety element Compression – Diesel 3150–3250 RPM 1150 RPM

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543 Bobcat Loader Operation & Maintenance Manual

LOADER SPECIFICATIONS (Cont’d) 543Operation&MaintenanceManual#6722584–SpecificationSection

HYDRAULIC SYSTEM Hydraulic Pump . . . . . . . . . . . . . . . . . . . . .

Pump Capacity . . . . . . . . . . . . . . . . . . . . .

System Main Relief . . . . . . . . . . . . . . . . . .

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine driven gear type 8.0 GPM (30,3 L/min.) @ 3000 RPM 1575 PSI (10860 kPa) Full flow, replaceable 10 micron paper in return line

Hydraulic Cylinders . . . . . . . . . . . . . . . . . . .

Doubleacting

Bore Diameter: Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . .

Rod Diameter: Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . .

Stroke: Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . .

2.00 (50,8) 3.00 (76,2) 1.25 (31,8) 1.50 (38,1) 22.2 (564) 12.4 (315)

Control Valve . . . . . . . . . . . . . . . . . . . . . . .

Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . .

3–spool, open center, series type, W/float detent on lift and detent on auxiliary SAE standard tubes, hoses & fittings

Hydraulic Function Time: Raise Lift Arms to Maximum Height . . . .

Lower Lift Arms from Maximum Height .

Move Bucket to Dump Position . . . . . . . .

Move Bucket to Retracted Position . . . .

4.1 Seconds 3.5 Seconds 2.5 Seconds 1.9 Seconds

Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bobcat Fluid (P/N 6563328). If fluid is not available use 10W–30 or 10W–40 Class SE Motor Oil for temperatures above 0_F (18_C) & 5W–30 for temperatures below 0_F (–18_C)

ELECTRICAL Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Belt drive, 55 amps. Open 12 volt, 425 cold crank amps. @ 0°F (–18°C) 75 min. reserve capacity 12 volt

DRIVE SYSTEM Transmission . . . . . . . . . . . . . . . . . . . . . . .

Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Total Engine to Wheel Reduction . . . . . .

Tandem hydro. pumps infinitely variable, driving 2 fully reversing hydro. motors #60 HS roller chains & sprockets in sealed chaincase with oil lubrication 42:6:1

CAPACITIES Cooling System . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil W/Filter . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir . . . . . . . . . . . . . . . . . .

Hydraulic/Hydrostatic System . . . . . . . . .

Chaincase Reservoir . . . . . . . . . . . . . . . .

9 qts. (8,5 L) 13 gals. (49 L) 4 qts. (3,8 L) 3.5 ga;s/ (13,2 L) 6 gals. (122,7 L) 4 gals. (15 L)

TIRES Standard (Flotation) . . . . . . . . . . . . . . . . .

Pressure . . . . . . . . . . . . . . . . . . . . . . . . . .

27 x 8.50–15, 4 Ply Rating Nylong with bar lug tread 33–37 PSI (228–255 kPa)

–68–

543 Bobcat Loader Operation & Maintenance Manual

WARRANTY 400–900 Series Bobcat Loaders The Melroe Company warrants to its authorized dealer and authorized dealers of Melroe Equipment, Ltd., who in turn warrants to the original buyer (owner) that each new Bobcat Loader will be free from proven defects in material and workmanship for 12 months after delivery to the owner.

During the warranty period, the authorized selling Melroe dealer shall repair or replace, at his option, without charge for parts and labor, any part of the Melroe product which fails because of defects in material and workmanship. The owner shall provide the authorized dealer with prompt written notice of the defect and allow reasonable time for replacement or repair. Melroe may, at its option, request failed parts to be returned to the factory. Travel time of mechanics and transportation of the Melroe product to the authorized Bobcat Loader dealer for warranty work are the responsibility of the owner.

The warranty does not apply to tires or other trade accessories not manufactured

by Melroe. The owner shall rely solely on the existing warranty, if any, of the respective manufacturers thereof. Warranty does not cover replacement of scheduled service items such as oil, filters, tune–up parts, and other high–wear items. The warranty does not cover damages resulting from abuse, accidents, alterations, air flow obstructions, or failure to maintain or use the Melroe product according to the instructions applicable to it.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES (EXCEPT THOSE OF TITLE), EXPRESSED OR IMPLIED, AND THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL THE AUTHORIZED SELLING DEALER OR MELROE BE LIABLE FOR DOWNTIME EXPENSES, LOSS OF MACHINE USE OR OTHER INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES.

6570162 (1–96)

Printed in U.S.A.