A Service Manual (sometimes referred to as a Repair, Technical, Workshop
or Shop Manual) is often
large and broken down in to sections for different parts of your equipment.
Service
manuals cover absolutely every aspect of your machine unless mentioned
otherwise. Sometimes, the
engine is covered in a separate service manual that is written specifically for
the
engine. Most of the time though, it’s included in the main service manual. A
service manual will
arm you with the same exact information that your local service center has and
includes
electrical and hydraulic diagrams and which are usually color and or large
foldout pages.
Most OEM service manuals will also include troubleshooting flow charts, error
codes and
exploded views of components which are a great help for disassembly and
re-assembly.

An Operator’s Manual typically describes basic equipment operation and
maintenance. This
is the manual distributed with your equipment at the time of purchase from the
dealer.

• MAINTENANCE SAFETY
• CONTENTS
• FOREWORD
• SAFETY INSTRUCTIONS
• PREVENTIVE MAINTENANCE
• INTRODUCTION
• Serial Number Identification
• Loader Serial Number
• Engine Serial Number
• Pre–Delivery Inspection
• Thirty Hour Inspection
• SERVICE SCHEDULE
• ENGINE SERVICE (General)
• Air Cleaner Service
• Fuel System
• Engine Lubrication System
• Replacement Of The Engine Oil And Filter
• Engine Cooling System
• ELECTRICAL SYSTEM
• Electrical System Service
• Using An Extra Battery (Booster Starting)
• Installing New Battery
• HYDRAULIC/HYDROSTATIC FLUID
• Replacing The Hydraulic/Hydrostatic Filter
• Checking And Adding Hydraulic/Hydrostatic Fluid
• Removing The Hydraulic/Hydrostatic Fluid
• FINAL DRIVE TRANSMISSION (Chaincase)
• Checking Chaincase Fluid
• SPARK ARRESTOR MUFFLER
• Cleaning The Spark Arrestor Muffler
• OPERATOR GUARD
• LUBRICATION OF THE LOADER
• TRANSPORTING THE BOBCAT LOADER
• Loading The Bobcat Loader
• Fastening The Loader To TheTransport Vehicle
• LIFT ARM STOP
• STOPPING THE BOBCAT LOADER
• HYDRAULIC SYSTEM
• HYDRAULIC / HYDROSTATIC SCHEMATICS
• TROUBLESHOOTING
• HYDRAULIC SYSTEM INFORMATION
• 37° Flare Connections
• Straight Thread O–Ring Fitting
• Tubelines and Hoses
• HYDRAULIC CONTROL VALVE
• Relief Valve
• Checking The Relief Valve
• Removal Of The Relief Valve
• Installation Of The Relief Valve
• Removal Of The Hydraulic Control Valve
• Disassembly Of The Hydraulic Control Valve
• Detent Mechanism
• Assembling the Hydraulic Control Valve
• Installing the Hydraulic Control Valve
• HYDRAULIC PUMP
• Checking Output Of The Hydraulic Pump
• Removal Of The Hydraulic Pump
• Disassembly Of The Hydraulic Pump
• Inspection Of The Hydraulic Pump
• Assembling The Hydraulic Pump
• Installing The Hydraulic Pump
• Start–Up Procedure For The Hydraulic Pump
• LIFT CYLINDERS
• Checking The Lift Cylinders
• Removing The Lift Cylinder
• Disassembly Of The Hydraulic Cylinder
• Assembly Of The Hydraulic Cylinder
• Installation Of The Lift Cylinder
• TILT CYLINDER
• Checking The Tilt Cylinder
• Removing The Tilt Cylinder
• Installation Of The Tilt Cylinder
• HYDRAULIC/HYDROSTATIC RESERVOIR
• Removing The Hydraulic/Hydrostatic Reservoir
• Installation Of The Hydraulic/Hydrostatic Reservoir
• OIL COOLER
• Removing The Oil Cooler (540)
• Installation Of The Oil Cooler (540)
• Removing The Oil Cooler (543)
• Installing The Oil Cooler (543)
• 10 MICRON FILTER BY–PASSVALVE
• Removing The By–Pass Valve
• Installation Of The By–Pass Valve
• CONTROL PEDAL, LINKAGE AND LOCKS
• Removing The Control Pedal
• Adjusting The Control Pedal
• Pedal Lock Linkage
• HYDROSTATIC SYSTEM
• TROUBLESHOOTING
• HYDROSTATIC SYSTEM INFORMATION
• High Pressure Relief Replenishing Valves Function
• STEERING LEVERS
• Removing Steering Levers
• Repairing The Steering Levers
• Installing The Steering Levers
• STEERING LINKAGE
• Adjustment Of The Steering Linkage
• Removing The Steering Linkage
• Repairing The Pintle Lever
• Installing The Steering Linkage
• PORT BLOCK
• Removing The Port Block
• Installing The Port Block
• By–Pass Valve
• HYDROSTATIC MOTOR
• Removing The Hydrostatic Motor
• Disassembly Of The Hydrostatic Motor
• Inspection Of The Hydrostatic Motor
• Assembling The Hydrostatic Motor
• Installing The Hydrostatic Motor
• Start–Up Procedure For The Hydrostatic Motor
• HYDROSTATIC PUMP
• Checking The High Pressure Relief Replenishing Valves
• Checking The Charge Pressure
• Cold Weather By–Pass Valve
• Removing The Hydrostatic Pumps
• Disassembly Of The Hydrostatic Pumps
• Inspection Of The Hydrostatic Pumps
• Assembling The Hydrostatic Pumps
• Installing the Hydrostatic Pumps
• Hydrostatic Pump Start–Up Procedure
• DRIVE SYSTEM
• BRAKES
• Parking Brake Adjustment
• Parking Brake Removal
• Parking Brake Inspection
• Parking Brake Installation
• FINAL DRIVE CHAINS
• Remove The Drive Chain(s)
• Installing The Drive Chain(s)
• AXLES AND BEARINGS
• Removing Axle(s) and Bearings
• Assembly Of The Axle
• Axle And Bearing Installation
• CHAINCASE FLUID
• Replacing Chaincase Fluid
• MAIN FRAME
• OPERATOR GUARD
• Raising The Operator Guard
• Lowering The Operator Guard
• Jumper Start Switch
• Removing The Operator Guard
• Installing The Operator Guard
• LIFT ARMS
• Removing The Lift Arms
• Installing The Lift Arms
• BOB–TACH
• Removing The Bob–Tach
• Disassembly Of The Bob–Tach
• Assembly Of The Bob–Tach
• Installing The Bob–Tach
• REAR DOOR
• Removing The Rear Door (Early Model)
• Removing The Rear Door (Later Models)
• Installing The Rear Door
• Adjusting The Rear Door Latch
• FUEL TANK
• Removing The Fuel Tank
• Installing The Fuel Tank
• ELECTRICAL SYSTEM
• ELECTRICAL SCHEMATICS
• TROUBLESHOOTING
• ELECTRICAL SYSTEM INFORMATION
• Electrical Circuitry
• Safety Procedures For The Batteries
• Precautions For The Alternator
• BATTERY
• Removing The Battery
• Installing The Battery
• WIRE HARNESS FOR THE OPERATOR GUARD
• Removing The Wire Harness For The Operator Guard
• Installing The Wire Harness For The Operator Guard
• WIRE HARNESS FOR THE ENGINE
• ALTERNATOR SYSTEM (540)
• Checking the A.C. Voltage
• Replacement Of The Stator
• ALTERNATOR SYSTEM (543)
• Belt Adjustment For The Alternator
• Checking The Alternator
• Removing The Alternator
• Repairing The Alternator
• Installing The Alternator
• STARTER (540)
• Checking The Starter
• Removing The Starter
• Repairing The Starter
• STARTER (543)
• Checking The Starter
• Removing The Starter
• Repairing The Starter
• Installing The Starter
• ENGINE SERVICE
• 540 KOHLER ENGINE SERVICE
• TROUBLESHOOTING
• CHECKS & ADJUSTMENTS
• Oil Pressure
• Valve Clearance
• Compression
• Throttle And Governor Linkage
• Ignition System
• Spark Plugs
• CARBURETOR & FUEL SHUT–OFF SOLENOID
• Removing The Carburetor
• Disassembly And Inspection Of The Carburetor
• Assembly Of The Carburetor
• Fuel Shut–off Solenoid
• GOVERNOR
• Removing The Governor
• Installing The Governor
• ENGINE AND HEAT SHIELD
• Removing The Engine
• Installation Of The Engine
• Removing The Heat Shield
• Installing The Heat Shield
• RECONDITIONING THE VALVES
• Repair Of The Valves And Guides
• TIMING COVER, TIMING GEARS AND CAMSHAFT
• Timing Cover
• Timing Gears
• Camshaft And Tappets
• OIL PUMP AND RELIEF VALVE
• Relief Valve
• Oil Pump
• Adjusting Gear Clearance For The Oil Pump
• PISTONS, RODS AND CRANKSHAFT
• Removing Pistons, Rods And Crankshaft
• Crankshaft Bearing And End Play
• CYLINDER HEAD
• INTAKE AND EXHAUST MANIFOLD
• FLYWHEEL
• 543 ISUZU ENGINE SERVICE
• TROUBLESHOOTING
• FUEL SYSTEM
• Fuel Filter
• Removing The Air From The Fuel System
• Fuel Lift Pump
• Removal Of The Fuel Injection Pump
• Fuel Injection Pump Drive Gear
• Installation And Timing Of The Fuel Injection Pump
• Fuel Injection Pump Reservoir
• Fuel Injector Nozzles
• Removing The Fuel Injector Nozzles
• Checking The Fuel Injector Nozzles
• Disassembly Of The Fuel Injector Nozzle
• Inspection Of The Fuel Injector Nozzle
• Assembling The Fuel Injectors Nozzle
• nstallation Of The Fuel Injector Nozzles
• ENGINE, BLOWER HOUSING AND RADIATOR
• Removing The Engine
• Installing The Engine
• Installing The Blower Housing
• Removing The Radiator
• Installation Of The Radiator
• ENGINE OVERHAUL
• Disassembly Of The Engine
• ROCKER ARMS AND SHAFT
• Disassembly Of The Rocker Arms
• Inspection Of The Rocker Arms
• CYLINDER HEAD
• Disassembly Of The Cylinder Head
• Inspection Of The Cylinder Head
• Inspection Of The Combustion Chambers
• Inspection And Correction Of The Valves & Guides
• Inspection Of The Valve Springs
• Inspection Of The Push Rods And Tappets
• Installation Of The Hot Plugs
• Assembly Of The Valve System
• CYLINDER BLOCK
• Inspection Of The Cylinder Block
• Correction Of The Cylinder Bores
• PISTONS AND PISTON RINGS
• Disassembly Of The Piston And Rings
• Inspection Of The Pistons
• Inspection Of The Connecting Rods & Bearings
• Assembly Of The Piston & Connecting Rod
• Inspection Of The Connecting Rod Bearings
• CRANKSHAFT
• Inspection Of The Crankshaft And Bearings
• CAMSHAFT
• Inspection Of The Camshaft
• TIMING GEAR
• Inspection Of The Timing Gear
• MANIFOLD ASSEMBLY
• Inspection Of The Manifold Assembly
• OIL PUMP AND OIL FILTER ASSEMBLY
• Disassembly Of The Oil Pump
• Inspection Of The Oil Pump
• Oil Filter Assembly
• Inspection Of The Oil Filter Assembly
• WATER PUMP
• Disassembly Of The Water Pump
• Inspection Of The Water Pump
• Assembly Of The Water Pump
• ASSEMBLY OF THE ENGINE
• ENGINE FLYWHEEL
• Removing The Flywheel
• Installing The Flywheel
• TECHNICAL DATA
• 540 LOADER SPECIFICATIONS
• Specifications
• Engine
• Loader Hydraulics
• Electrica
• Drive System
• Capacities
• Tires
• 543 LOADER SPECIFICATIONS
• Specifications
• Engine
• Loader Hydraulics
• Electrical
• Drive System
• Capacities
• Tires
• ENGINE SPECIFICATIONS
• 540 LOADER (KOHLER)
• Engine (General)
• Cylinder Bore
• Crankshaft
• Camshaft
• Connecting Rod
• Piston, Pin & Rings
• Valves, Guides & Tappets
• Engine Torque
• 543 LOADER (ISUZU)
• Cylinder Block
• Cylinder Head
• Piston
• Piston Ring
• Connecting Rod
• Crankshaft
• Camshaft
• Timing Gear
• Valve
• Valve Spring
• Tappet
• Oil Pump and Relief Valve
• Water Pump
• Fuel Lift Pump
• Fuel Injector
• Engine Torque
• TORQUE SPECIFICATIONS
• Engine Group – 540 Loader
• Engine Group – 543 Loader
• Engine Group – 543 Loader
• Seat Bar, Fuel Tank & Panel Group
• Steering Levers, Linkage & Pedal Group
• Mainframe Group
• Hydrostatic Group – 540 Loader
• Hydrostatic Group – 543 Loader
• Hydraulic Group
• HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
• Hydraulic/Hydrostatic Fluid
• DECIMAL AND MILLIMETER EQUIVALENTS
• U.S. TO METRIC CONVERSION
• STANDARD TORQUE SPECIFICATIONS FOR BOLTS
• ALPHABETICAL INDEX
• SERVICE MANUAL REVISIONS
• 540–1
• 540–2
• 540–2
• 540–3
• 540–4
• 540–5
• 540–6