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
• ALPHABETICAL INDEX
• CONTENTS
• FOREWORD
• SAFETY INSTRUCTIONS
• PREVENTIVE MAINTENANCE
• INTRODUCTION
• Serial Number Identification
• Loader Serial Number
• Engine Serial Number
• Delivery Report
• SERVICE SCHEDULE
• ENGINE SERVICE (General)
• Air Cleaner Service (540)
• Air Cleaner Service (543)
• Fuel System
• Replacement of the Engine Oil and Filter
• Engine Cooling System (540)
• Engine Cooling System (543)
• ELECTRICAL SYSTEM
• Electrical System Service
• Using an Extra Battery (Booster Starting)
• Installing New Battery
• SPARK ARRESTOR MUFFLER
• HYDRAULIC/HYDROSTATIC SYSTEM
• Replacing The Hydraulic Filter Element
• Checking & Adding Hydraulic/HydrostaticFluid
• Removing The Hydraulic/Hydrostatic Fluid
• FINAL DRIVE TRANSMISSION (CHAINCASE)
• Checking/Adding Chaincase Fluid
• TIRE MAINTENANCE
• Tire Rotation
• Wheel Nuts
• LUBRICATION OF THE LOADER
• Lubrication Of The Loader
• ROLL OVER PROTECTION STRUCTURE (ROPS & FOPS)
• Operator Cab
• TRANSPORTING THE BOBCAT LOADER
• Loading The Bobcat Loader
• Fastening The Loader To The Transport Vehicle
• Lifting The Loader
• Towing The Loader
• LIFT ARM SUPPORT DEVICE
• Installing the Approved Lift Arm Support Device
• 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
• Check 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 CONTROL VALVE (MELROE)
• Relief Valve
• Check The Relief Valve
• Adjusting The Relief Valve
• Relief Valve Service
• Installation Of A New Relief Valve
• Removal Of The Hydraulic Control Valve (Melroe)
• Disassembly Of The Control Valve
• Inspection Of The Control Valve
• Assembly Of The Control Valve
• Installation Of The Control Valve
• HYDRAULIC PUMP
• Checking Output Of Hydraulic Pump
• Removal Of The Hydraulic Pump
• Disassembly Of The Hydraulic Pump
• Inspection Of The Hydraulic Pump
• Assembling The Hydraulic Pump
• Installation To 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)
• Installation Of The Oil Cooler (543)
• 10 MICRON FILTER BY–PASS VALVE
• Remove The By–Pass Valve
• Installation Of The By–Pass Valve
• CONTROL PEDAL, LINKAGE AND LOCKS
• Removing The Control Pedal
• Installation Of 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
• Charge By–Pass Valve
• HYDROSTATIC MOTOR
• Removing The Hydrostatic Motor
• Motors With Keyed–Shaft
• Motors With Splined–Shaft
• Disassembly of the Hydrostatic Motor
• Hydrostatic Motor Inspection
• Assembly Of The Hydrostatic Motor
• Installing The Hydrostatic Motor
• Keyed–Shaft Motors
• Splined–Shaft Motors
• Start–Up Procedure For The Hydrostatic Motor
• HYDROSTATIC PUMP
• Checking The High Pressure Relief Replenishing Valves
• Checking The Charge Pressure
• Removing The Hydrostatic Pump
• Disassembly Of The Hydrostatic Pump
• Inspection Of The Hydrostatic Pumps
• Assembling The Hydrostatic Pumps
• Installing The Hydrostatic Pumps
• Start–Up Procedure For The Hydrostatic Pump
• TOWING THE BOBCAT LOADER
• Installation Of The Tool For The High Pressure Relief Valves
• DRIVE SYSTEM
• PARKING BRAKE
• 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 CAB
• Raising The Operator Cab
• Lowering The Operator Cab
• Jumper Start Switch
• Removing The Operator Cab
• Removing The Gas Cylinder
• Installing The Operator Cab
• 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
• Installing The Rear Door
• Adjusting The Rear Door Latch
• FUEL TANK
• Removing The Fuel Tank
• Installing The Fuel Tank
• SEAT BAR
• Removal And Installation
• SEAT BAR SYSTEM
• Seat Bar Inspection
• Seat Bar Maintenance
• PEDAL LOCK LINKAGE
• Adjustment
• REAR WINDOW
• Installing Rear Window
• 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 CAB
• Removing The Wire Harness For The Operator Cab
• Installing The Wire Harness For The Operator Cab
• WIRE HARNESS FOR THE ENGINE
• ALTERNATOR SYSTEM (540)
• Checking The Alternator
• Replacing The Stator
• ALTERNATOR SYSTEM (543)
• Adjusting The Alternator Belt
• Alternator Output Test (New Style)
• Rectifier (Diode) Test (New Style)
• Alternator Regulator Test (New Style)
• Checking The Alternator (Early Models)
• Parts Identification (New Style)
• Disassembly And Assembly (New Style)
• Stator Continuity Test
• Stator Ground Test
• Rotor Continuity Test
• Rotor Ground Test
• Rectifier Continuity (Diode) Test
• Removing The Alternator (Early Models)
• Repairing The Alternator (Early Models)
• Installing The Alternator (Early Models)
• 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
• ENGINE SERVICE (540) KOHLER
• TROUBLESHOOTING
• CHECKS AND ADJUSTMENTS FOR THE ENGINE
• Engine Oil Pressure
• Valve Clearance
• Compression
• Throttle And Governor Linkage
• Ignition System
• Spark Plugs
• CARBURETOR & FUELSHUT–OFF SOLENOID
• Removing The Carburetor
• Disassembly And Inspection Of The Carburetor
• Assembly Of The Carburetor
• Fuel Shut–off Solenoid
• Non–Metallic Bodied Fuel Pumps
• GOVERNOR
• Removing The Governor
• Installing The Governor
• ENGINE AND HEAT SHIELD
• Removing The Engine
• Installing The Engine
• Removing The Heat Shield
• Installing The Heat Shield
• RECONDITIONING THEVALVES
• 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
• ENGINE SERVICE (543 & 543B) KUBOTA
• TROUBLESHOOTING
• FUEL SYSTEM
• Replacing The Fuel Filter
• To Remove The Air From The Fuel System
• Fuel Injection Pump
• Checking The Injection Pump
• Installation
• Timing The Fuel Injection Pump
• Fuel Injector Nozzles
• Removal
• Checking The Fuel Injector Nozzles
• Installation
• Checking Glow Plugs
• ENGINE AND ATTACHING PARTS
• Removing The Engine
• Installing The Engine
• Engine Muffler
• Engine Radiator Removal
• Engine Radiator Installation
• Engine Blower Housing Removal
• Engine Blower Housing Installation
• Engine Blower Fan And Flywheel Removal
• Engine Blower Fan And Flywheel Installation
• CYLINDER HEAD
• Removing The Cylinder Head
• Disassembly Of The Cylinder Head
• Servicing The Cylinder Head
• Assembly Of The Cylinder Head
• Installing The Cylinder Head
• Adjusting the Compression Release Mechanism
• REPAIRING THE ENGINE
• Removing The Gear Case
• Removing The Timing Gear, Camshaft & Oil Pump
• Removing Pistons And Crankshaft
• Servicing The Timing Gear And The Camshaft
• Servicing The Connecting Rods And Pistons
• Servicing The Crankshaft
• Servicing The Cylinder Liners
• Servicing The Oil Pump
• Servicing The Water Pump
• ASSEMBLY OF THE ENGINE
• Installing The Crankshaft
• Installing The Pistons
• Installing The Camshaft And Timing Gears
• Installing The Gear Case Cover
• TECHNICAL DATA
• (540) KOHLER LOADER SPECIFICATIONS
• Operation & Performance
• Engine
• Loader Hydraulics
• Electrical
• Drive System
• Capacities
• Tires
• ENGINE SPECIFICATIONS – 540 LOADER (KOHLER)
• Engine (General)
• Cylinder Bore
• Crankshaft
• Camshaft
• Connecting Rod
• Piston, Pin And Rings
• Valves, Guides & Tappets
• Engine Torque
• 543 & 543B KUBOTA LOADER SPECIFICATIONS
• Operation & Performance
• Engine
• Loader Hydraulics
• Electrical
• Drive System
• Capacities
• Tires
• ENGINE SPECIFICATIONS – 543-543B LOADER
• Fuel Injector Nozzles
• Fuel Injection Pump
• Cylinder Head
• Valves
• Valve Springs
• Rocker Arms
• Camshaft
• Cylinders
• Piston Rings
• Piston
• Crankshaft
• Oil Pump
• Thermostat
• Engine Torque
• Grinding Specifications for the Crankshaft
• TORQUE SPECIFICATIONS
• Engine Group – 540 Loader
• Engine Group – 543 Loader
• Fuel System Group
• Steering Levers & Panel Group
• Bob–Tach & Lift Arm Group
• Seat Bar & Pedal Group
• Brake, Chaincase & Axle Group
• Hydraulic Group
• Operator Cab, Main Frame & Rear Door Group
• Hydrostatic Group–540 Loader
• Hydrostatic Group–543 Loader
• HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
• Hydraulic/Hydrostatic Fluid
• DECIMAL AND MILLIMETER EQUIVALENTS
• U.S. TO METRIC CONVERSION
• STANDARD TORQUE SPECIFICATIONS FOR BOLTS
• SERVICE MANUAL REVISIONS
• 540–3
• 540–4
• 540–5
• 540–6
• 540–7
• 540–8
• 540–9
• 540–11
• 540–13
• 540–14
• 540–15
• 540–16
• 540–17
• 540–1 Thru 540–17
• 540–18
• 540–19