540-543 6566532 SM 11-94

5 5
4 4
0 3
Service
Manual
5
Dealer Copy -- Not for Resale

540 (S/N 501012001 & Above)
4
543 (S/N 502412001 & Above)
543B (S/N 511111001 & Above)
3
B
6566532 (11–94) Printed in U.S.A. © Melroe Company 1994
1 of 322
2 of 322
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING 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. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
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-10731a B-12365 B-7469

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG

B-11799 B-15231 B-15280
Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-6590 B-6580 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
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. The Service Safety Training Course is available from your Bobcat dealer.
MSW01-0805
3 of 322
4 of 322
ALPHABETICAL INDEX
Subject Page Subject Page
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
ALTERNATOR SYSTEM (540) . . . . . . . . . . . . . . . . . . 6–1 RECONDITIONING THE VALVES . . . . . . . . . . . . . . 7A–1
ALTERNATOR SYSTEM (543) . . . . . . . . . . . . . . . . . . 6–1 REPAIRING THE ENGINE . . . . . . . . . . . . . . . . . . . . 7B–1
ASSEMBLY OF THE ENGINE . . . . . . . . . . . . . . . . . 7B–1 ROLLOVER PROTECTION STRUCTURE
AXLES & BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 (ROPS & FOPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 SEAT BAR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
CARBURETOR & FUEL SHUT OFF SOLENOID . 7A–1 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . 1–1
CHAINCASE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 STANDARD TORQUE SPECIFICATIONS
CHECKS & ADJUSTMENTS FOR THE ENGINE . 7A–1 FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–1
CONTROL PEDAL, LINKAGE AND LOCKS . . . . . . 2–1 STARTER (540) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–1 STARTER (543) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–1 STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
DECIMAL AND MILLIMETER EQUIVALENTS . . . 8C–3 STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . 1–1
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 1–1
10 MICRON FILTER BY–PASS VALVE . . . . . . . . . . . . 2–1
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . 6–1
ENGINE AND ATTACHING PARTS . . . . . . . . . . . . . 7B–1 TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
ENGINE & HEAT SHIELD . . . . . . . . . . . . . . . . . . . . . 7A–1 TIMING COVER, TIMING GEARS & CAMSHAFT 7A–1
ENGINE SERVICE (General) . . . . . . . . . . . . . . . . . . . 1–1 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
ENGINE SERVICE (KOHLER – 540) . . . . . . . . . . . 7A–1 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . 8C–1
TOWING THE BOBCAT LOADER . . . . . . . . . . . . . . . . 3–1

ENGINE SERVICE (KUBOTA – 543) . . . . . . . . . . . . 7B–1
ENGINE SPECIFICATIONS TRANSPORTING THE BOBCAT LOADER . . . . . . . . 1–1
540 LOADER (KOHLER) . . . . . . . . . . . . . . . . . . . . . 8A–1 TROUBLESHOOTING . . . . . 2–1, 3–1, 6–1, 7A–1, 7B–1
ENGINE SPECIFICATIONS–
543 LOADER (KUBOTA) . . . . . . . . . . . . . . . . . . . . . 8B–1 U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . 8C–4
FINAL DRIVE CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 WIRE HARNESS FOR THE ENGINE . . . . . . . . . . . . . 6–1
FINAL DRIVE TRANSMISSION (Chaincase) . . . . . . 1–1 WIRE HARNESS FOR THE OPERATOR CAB . . . . . 6–1
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–1
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . 2–1

HYDRAULIC CONTROL VALVE (MELROE) . . . . . . 2–1
HYDRAULIC/HYDROSTATIC FLUID
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–2
HYDRAULIC/HYDROSTATIC RESERVOIR . . . . . . . 2–1
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . 1–1
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . 2–1
HYDROSTATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . 3–1
INTAKE & EXHAUST MANIFOLD . . . . . . . . . . . . . . 7A–1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . 1–1
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
LOADER SPECIFICATIONS–540 . . . . . . . . . . . . . . 8A–1
LOADER SPECIFICATIONS–543 . . . . . . . . . . . . . . 8B–1
LUBRICATION OF THE LOADER . . . . . . . . . . . . . . . 1–1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

OIL PUMP & RELIEF VALVE . . . . . . . . . . . . . . . . . . 7A–1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

PEDAL LOCK LINKAGE . . . . . . . . . . . . . . . . . . . . . . . 5–1
PISTONS, ROD AND CRANKSHAFT . . . . . . . . . . . 7A–1
PORT BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
540, 543 Loader
5 of 322 Service Manual
540, 543 Loader

6 of 322 –3–0– Service Manual
CONTENTS PREVENTIVE
MAINTENANCE
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HYDRAULIC
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SYSTEM
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HYDROSTATIC
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SYSTEM
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DRIVE

SYSTEM
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAIN
FRAME

ELECTRICAL
SYSTEM
ENGINE
SERVICE
TECHNICAL
DATA
ALPHABETICAL
INDEX
Revised Oct. 94 540, 543 Loader

540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–ContentsSection
540, 543 Loader

FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. Enclosure door latches must

(Including sidescreens) is in open and close freely.
good condition and is not
modified.
2. Check that ROPS mounting 10. Bob–Tach wedges and

hardware is tightened and is linkages must function
Melroe approved. correctly and be in good
condition.
3. The seat belt must be correctly 11. Safety treads must in good
installed, functional and in condition.

good condition.
4. The seat bar and pedal 12. Check for correct function of
interlocks must be correctly indicator lamps (Optional on
adjusted, clean and lubricated. some models).
5. Machine signs must be legible 13. Check hydraulic fluid level,

and in the correct location. engine oil level and fuel supply.
6. Steering levers and foot pedals 14. Inspect for fuel, oil or hydraulic
must return to neutral. fluid leaks.
7. Check for correct function of 15. Lubricate the loader.

the work lights.
8. The parking brake must 16. Check the condition of the

function correctly. battery and cables.
540, 543 Loader

9 of 322 Oct. 94
Revised Service Manual
17. Inspect the air cleaner for
damage or leaks. Check the
condition of the element.
18. Check the electrical charging

system.
19. Check tires for wear and

pressure.
20. Inspect for loose or broken

parts or connections.

21. Operate the loader and check
all functions.
22. Check for any field

modification not completed.
Recommend to the owner that all

necessary corrections be made
before the machine is returned to
service.
540, 543 Loader

Revised Oct. 94
SAFETY INSTRUCTIONS
Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual,
Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Failure
to follow instructions can cause injury or death.
W–2003–0797
The following publications provide information on the safe use and maintenance of the loader and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.
• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
• The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the
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 dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish version.
• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.
Warnings on the machine and in the This notice identifies procedures

manuals are for your safety. Failure to which must be followed to avoid
obey warnings can cause injury or damage to the machine.
death. I–2019–0284
W–2044–1285
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
SI05–0498
540, 543 Loader

Revised Oct. 98
SAFETY INSTRUCTIONS (Cont’d)
• Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hearing
protection or loader special applications kit are required for some work. See your dealer for Melroe Safety equipment.
• Know where fire extinguisher and first aid kit are located and how to use them.
• Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, 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.
• Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or anti–freeze.
• Do not use ether or starting fluids on engines which have glow plugs. These starting aids can cause explosion and 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 or Service Manuals for connecting the battery.
A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].
SI06–0398 P–03705
540, 543 Loader

12 of98
Revised Oct. 322 Service Manual
SAFETY INSTRUCTIONS
PREVENTIVE MAINTENANCE PREVENTIVE
MAINTENANCE
Paragraph Page
Number Number
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 1–9
ENGINE SERVICE (General) . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 1–3
FINAL DRIVE TRANSMISSION (Chaincase) . . . . . . . . . . . . . 1–7 1–14

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . 1–6 1–13
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 1–1

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 1–12 1–19
LUBRICATION OF THE LOADER . . . . . . . . . . . . . . . . . . . . . . 1–9 1–16
ROLLOVER PROTECTION STRUCTURE

(ROPS & FOPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–10 1–16
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 1–2

SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . 1–5 1–12
STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . 1–13 1–19
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 1–15
TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . 1–11 1–17
DO NOT service the Bobcat loader

without instructions or taking the
necessary safety precautions.
Before working on the loader, see
WARNING the warnings and instructions at the
beginning of this Service Manual.
After making the repair or
adjustment, always check the
function of the loader. Failure to
obey warnings may cause injury or
death.

13 of 322 –1––1– Service Manual
540, 543 Loader

SAFETY INSTRUCTIONS
PREVENTIVE MAINTENANCE
1–1 INTRODUCTION
The Preventive Maintenance Section of
this Service Manual gives general
maintenance procedure for the Bobcat
loader. The other sections of the
Service Manual will give the detailed
description needed for disassembly and
assembly and when replacement parts
are needed.
Engine Serial
Number
B–05732 B–02882
Fig. 1–1 Loader Serial Number Fig. 1–2 Engine Serial Number (540)
1–1.1 Serial Number Identification

It is important to make correct reference to the Serial Number of the Bobcat loader
and/or engine when making repairs or ordering parts. It is possible that the present
loaders do not use all the same parts as the earlier loaders. It is possible that
different procedures are used for servicing repair.
1–1.2 Loader Serial Number

The Bobcat loader serial number plate location is on the inside of the left upright,
above the grill (Fig. 1–1).
Explanation of the Serial Number:
B–05839
XXXX M XXXX Fig. 1–3 Engine Serial Number (543)
Production Sequence (Series)

Factory Use Only
Model, Engine Version
1–1.3 Engine Serial Number

The engine serial number for the 540 (Kohler) Bobcat loader is located on the
blower housing at the right side of the engine (Fig. 1–2).
The engine serial number for the 543 (Kubota) Bobcat loader is located at the left
side of the engine at fuel injection pump (Fig. 1–3).
1–1.4 Delivery Report

The Delivery Report is to be filled out by the dealer and signed by the
owner/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.
Fig. 1–4 Delivery Report
540, 543 Loader

1–2 SERVICE SCHEDULE
Maintenance work must be done at regular intervals. Failure
to do so may result in damage to the Bobcat loader or the
engine. The SERVICE SCHEDULE is a guide for correct
maintenance of the Bobcat loader. DO NOT change this
Service Schedule unless the frequency of service is increased
when the Bobcat loader is operated in very hot, cold, dusty or DO NOT work on the loader with the lift arms in
corrosive conditions. a raised position without support by a lift arm
support device.
SERVICE SCHEDULE HOURS

543B
500
1000
100
250
8–10
50
540
543
ITEM SERVICE REQUIRED

Engine Air Cleaner Check the condition indicator. Make inspection of the air
cleaner system. Replace the element when the red ring shows
in the indicator window.
Engine Oil Check level and add oil as needed.
Engine Cooling System Check and clean as needed (Including oil cooler grill).
Engine Coolant System Check the coolant level and add as needed. Remove any
debris from the radiator grill area.
Tires Check for damage and check the tire pressure.

Operator Guard, Seat Belt and Check the operator guard fastening bolts to make sure they
Seat Bar are tight. Check the condition of the seat belt. Check the seat
bar for correct operation.
Safety Signs (Decals) Check for damaged decals. Replace any decals that are not
there.
Pivot Points Add lubricant to all fittings.
Hydraulic/Hydrostatic Fluid Check the fluid level and add the recommended fluid as
needed (See Section 8 for correct fluid).
Engine Oil and Filter Change, fill with new clean oil according to oil specification
chart and install new filter.
Battery Check the battery cables and the battery water level.
Control Pedals and Steering Check both for correct operation. Make repairs and adjust as
Levers needed.
Bob–Tach Check locking levers and wedges for condition and operation.
Brakes Check operation. Make adjustment as needed.
Chaincase Fluid Check level. Add fluid as needed.
Hydraulic/Hydrostatic Filter Replace the filter element.
Spark Arrestor Muffler Remove the plug and clean the spark chamber.
Engine Ignition System Check the points and timing. Replace the spark plugs.
Engine Air Housing Remove and clean housing and cooling fins.
Engine Air Cleaner System Check system for leaks. Replace element as needed.
Engine Fuel Filter Replace element.
U–Joint Add grease to the U–joint.
Seat Bar Lubricate the detent mechanism.
Steering Levers Add grease to the pivot bearings.
Chaincase Replace the fluid.
Hydraulic/ Hydrostatic System Replace the fluid. Clean the inlet screen and vent.
Revised Oct. 94
540, 543 Loader
SAFETY INSTRUCTIONS
1–3 ENGINE SERVICE (General)
Stop, cool and clean the engine

of flammable material. Never
service or adjust machine with
the engine running unless
instructed to do so by the
Service Manual.
Open the rear door to service the

engine. Pull the door latch up (Fig.
1–5) and turn to the left to release the B–05719 B–05718
door latch (Fig. 1–6). The door can
then be fully opened to get to the Fig. 1–5 Opening Door Latch Fig. 1–6 Opening Rear Door
engine area.
See Section 5 for the Door Latch
Adjustment.

Keep the rear door closed
except for service. Make sure
you close the door and fasten
the latch tightly before
operating the Bobcat loader.
B–05721 B–05720
Fig. 1–7 Air Cleaner Cup (540) Fig. 1–8 Air Cleaner Element (540)
1–3.1 Air Cleaner Service (540)

It is important to service the air cleaner at regular intervals for good engine
performance and long service life.
Service the air cleaner as follows:
1. Open the rear door.
2. Remove the dust cup and clean every day (Fig. 1–7).
3. Make replacement of the element only when the red ring shows in condition
indicator window (Fig. 1–9).
4. Clean the inside of the filter housing so that the element has a smooth
surface to contact at the seal. Check the filter housing for holes from
corrosion, especially if the Bobcat loader is used in fertilizer application.
A–02831
Fig. 1–9 Condition Indicator (540)
540, 543 Loader

Install the new filter element (Fig. 1–8, Page 1–3) and
tighten the wing nut. A 543
Install the dust cup and tighten the clamp (Fig. 1–7, Page
1–3).
Push the button at the condition indicator (Fig. 1–9, Page
1–3) to remove the red ring.
Check to make sure that all the hoses and clamps are
tight.
1–3.2 Air Cleaner Service (543)

It is important to service the air cleaner at regular intervals
for good engine performance and long service life. B–05836
Service the air cleaner as follows:

Remove the dust cup and clean every day [A].
B 543
Make replacement of the element only when it becomes

necessary. The large air cleaner element (outer) must be
replaced when the red ring shows in the window of the
condition indicator. DO NOT remove the inner filter.

NOTE: Before changing the air cleaner element,
push the button on the condition indicator
(Fig. A, Page 1–5), start the engine and if the
red ring still shows, then do the following
procedure.
B–05838
Remove the wing nut and remove the outer filter element
[B]. C
Make sure the inside of the filter housing has a smooth
surface for the seal to make contact. Check the filter
housing for holes from corrosion, especially if the Bobcat
loader is used in corrosive application.
Install the outer filter element [B]. Only replace the inner
filter element under the following conditions [C].
• Replace the inner filter element every third time the
outer filter is replaced.
• Replace the inner filter element when the red ring
still shows in the condition indicator window after
the outer filter is replaced. P–01693
543B: Record the operating hours of the loader on the

decal (Item 1) [D] inside the rear door.
D
Install the dust cup and tighten the clamp [A].
Push the button at the condition indicator (Fig. A, Item 1,
Page 1–5) to remove the red ring from the window.
Check that the hoses and clamps are tight.
Install the dust cup and tighten the clamp [A]. 1
P–01683

SAFETY INSTRUCTIONS
1–3.3 Fuel System
A
Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can
cause an explosion or fire.
W–2063–0887
1
Use 85 octane regular or unleaded gasoline in the engine B–05837
of the 540 Bobcat loader.
Use number 2 diesel fuel in the engine of the 543 Bobcat
loader. During very cold temperature conditions, number B 1
540
1 fuel is recommended.
To add fuel to the tank [B] or [C], use the following
procedure:
Use a clean, approved safety container to add the fuel.
The engine must be stopped and cool.

Add fuel only in an area that has free movement of air and
2
no sparks. NO SMOKING [D].
Use only clean fuel of the correct specifications.
Tighten the cap, (Item 1) [B] or [C], on the fuel tank. B–03994
540 Bobcat Loader:

There is a fuel filter, (Item 2) [B] in the fuel line by the fuel
C 543
shut–off valve. The fuel filter must be replaced every 250

hours of loader operation.
1
See Section 7A for the correct replacement procedure.
543 Bobcat Loader:
There is a fuel filter located on the left side of the engine.
The fuel filter must be replaced every 250 hours of the
loader operation.
See Section 7B for the correct replacement procedure.

1–3.4 Engine Lubrication System B–03854
Check the oil level each day.

D
B–03884
To check the oil level, stop the engine, open the rear door
and remove the dipstick [A] & [B].
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–PreventiveMaintenanceSectionPages1–6
A
NOTE: 543 Only: The dipstick may indicate an
incorrect level of oil when first removed.
Always (1) remove the dipstick, (2) wipe the
dipstick, (3) insert dipstick again and (4)
re–check the oil level.
B–05722

Keep the oil level between the marks on the dipstick [C].
DO NOT fill above the top mark. Use a good quality motor B–05841
oil that meets API Service Classification of SE, SF, CC,
CD or CE (See the chart below).
1–3.5 Replacement of the Engine Oil and Filter C
Replace the engine oil and filter every 50 hours of loader
operation. Keep Oil Level
Between These Marks
RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR ENGINE CRANKCASE)
C°–34–29 –23 –18 –13 –7 –1 +4 +10 +15 +21 +27 +32 +38 +43 +49 +54 +60
SAE 40 or 20W–50
SAE 10W–30/40
SAE 15W–40
A–01528
SAE 5W–30
SAE 30W
SAE 20W–20
SAE 10W
F°–30 –20 –10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +110+120+130+140
TEMPERATURE RANGE ANTICIPATED BEFORE

NEXT OIL CHANGE
(GASOLINE: USE API CLASSIFICATION SE OR SF)
(DIESEL: USE API CLASSIFICATION CC OR CD)
NOTE: Do not use multi viscosity oils in gasoline

engine unless ambient temperature is below
32° F.
SAFETY INSTRUCTIONS
To replace the engine oil and filter, use the following
procedure: A
Run the engine until it is at operating temperature. Stop
the engine. Open the rear door.
Remove the drain plug (Item 1) [A] or [B]. Drain the oil into
a container.
A–02832

1
B–05842
Added Oct. 94 540, 543 Loader

21 of 322 –1–6a– Service Manual
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–PreventiveMaintenanceSectionPages6a–6b
540, 543 Loader

22 of 322 –1–6b– Service Manual
SAFETY INSTRUCTIONS
1. Remove the oil filter. (Fig. 1–21
or Fig. 1–22.)
2. Clean the filter housing surface.
3. Install the drain plug. Remove

the fill cap. Add the correct
amount of oil to the engine (See
the Oil Chart for the correct oil).
4. Start the engine and let it run for

several minutes. Stop the
engine. Check the oil level. Add
oil if the level is not at the top A–02834 B–05842
mark on the dipstick. Fig. 1–21 Engine Oil Filter (540) Fig. 1–22 Engine Oil Filter (543)
1–3.6 Engine Cooling System

(540)

The oil cooler grill and engine cylinder
cooling fins must be kept clean and
free of debris or overheating will
result.
Use safety goggles when

using air pressure to clean the
grill area. DO NOT use cold B–05725
water on a hot engine.
Fig. 1–23 Cleaning Rear Door Grill
Use air pressure or water to clean the oil cooler (Fig. 1–23).
Remove the shrouding on the engine to clean the cooling fins. Make sure to wear
safety goggles when using air pressure or water spray for cleaning the fins.
Use a brush and scraper tool to remove the hard deposits on the cooling fins (Fig.
1–24).
NOTE: The oil cooler can be removed for better cleaning.
B–05726
Fig. 1–24 Cleaning Cooling Fins
540, 543 Loader

Make sure to replace all the covers and shrouding after
cleaning the engine. A
Never operate the engine with any of the covers

or shrouding removed.
1–3.7 Engine Cooling System (543) B–05844

The radiator grill area must be kept clean and free of
debris or overheating of the engine will result [C].
The cooling system has a coolant recovery tank. The
B
location of the tank is on the right upright in the engine
compartment [A]. Check the coolant level every day at
the coolant recovery tank. Correct level of the recovery
tank is 1/3 full when the engine is cold and 2/3 full when
the engine is operating temperature.
Add coolant at the recovery tank only.

NOTE: Protect the cooling system from freezing
temperatures by adding 50/50 (PRE–MIXED)
mixture of ethylene glycol and water to the
cooling system.
B–05846
Removing the coolant from the Cooling System, use

the following procedure:
C
Stop engine and allow to cool before adding

coolant or you can be burned.
W–2106–1285
P–01675
The valve to remove the coolant is on the left side of the

engine block [B]. D
Connect a hose to the valve or use a funnel to keep
coolant from getting into the engine compartment. 1
Remove the rear grill.
Remove the radiator cap (Item 1) [D]. The grill must be
removed.

SAFETY INSTRUCTIONS
Turn the valve so that the lever is toward the outlet of the valve.
To fill the cooling system:
1. Close the drain valve [B] (Page 1–8).

Water and
Baking Soda
2. Mix 50% water and 50% anti–freeze. Solution
3. Fill the radiator completely and install the radiator cap.
4. Install the grill.
5. Fill the coolant recovery tank 1/3 full.

A–02741
1–4 ELECTRICAL SYSTEM Fig. 1–28 Cleaning the Battery
1–4.1 Electrical System Service
1. Check the battery cables and make sure they are clean and tight. Check the
water level of the battery. Remove any acid or corrosion from the battery and
cables with a sodium bicarbonate and water solution (Fig. 1–28). Cover the
battery terminals and cable ends with grease.
2. Check the tension of the alternator belt (See Section 6 for the correct
procedure)

3. Check all wires for being broken.
NOTE: The warning lights (on the dash panel) will come ON when the key
switch is turned ON. When the engine is started, the warning lights
must go OFF. If they do not, stop the engine and find the problem.
1–4.2 Using an Extra Battery (Booster Starting)
Keep arcs, sparks, flames and

lighted tobacco away from batteries.
When jumping from booster battery
make final connection (negative) at
engine frame.
Do not jump start or charge a frozen
WARNING or damaged battery. Warm battery to
60°F. (16°C.) before connecting to a
charger. Unplug charger before
connecting or disconnecting cables
to battery. Never lean over battery
while boosting, testing or charging.
Battery gas can explode and cause
serious injury.
W–2066–1296
540, 543 Loader

25 of 322
Revised Oct. 98 –1–9– Service Manual
Connected To
The Starter
Connected To The
WARNING Engine For Ground Connected To The
Engine For Ground 4
Batteries contain acid which 2

burns eyes and skin on contact.
Wear goggles, protective
clothing and rubber gloves to
keep acid off body.
In case of acid contact, wash 1
immediately with water. In case 3
of eye contact get prompt LOADER
medical attention and wash eye BATTERY
with clean, cool water for at
least 15 minutes.
If electrolyte is taken internally EXTRA
drink large quantities of water Booster BATTERY
or milk! DO NOT induce Cables
vomiting. Get prompt medical B–03711
attention. W–2065–1296 Fig. 1–29 Connecting the Extra Battery
If it is necessary to use an extra battery to start the engine. BE CAREFUL! This

is a two–person operation. There must be one person in the operator’s seat and
one person to connect and disconnect the battery cables.
1. The ignition must be in the OFF position.

2. The battery to be used must be of the same voltage.
3. Battery terminals have identification marks. The positive terminal is marked
(+) and the negative terminal is marked (–).
4. The negative terminal (–) of the battery must be connected to the engine.

engine frame.
or damaged battery. Warm battery to
WARNING 60°F. (16°C.) before connecting to a
serious injury. W–2066–1296
5. Connect the end of the first cable to the positive terminal (+) of the booster
(Fig. 1–29, Item 1). Connect the other end of the same cable to the positive
terminal (+) of the loader battery (Fig. 1–29, Item 2).
6. Connect the end of the second cable to the negative terminal (–) of the
booster battery (Fig. 1–29, Item 3). Connect the other end of the second
cable to the engine (Fig. 1–29, Item 4). DO NOT connect the cable directly
to the negative terminal (–) of the loader battery. Connecting the cable
directly to the battery can cause a spark and destroy the battery and cause
personal injury.
7. Keep the cables away from the fans and belts.
NOTE: The operator must be in the operator’s seat and have the seat belt
fastened.
8. Start the engine.
9. After the engine has started, remove the cable connected to the engine (Fig.
1–29, Item 4).
10. Then remove the cable from the loader battery post positive terminal (+) (Fig.
1–29, Item 2).
540, 543 Loader

26 98
Revised Oct. of 322 –1–10– Service Manual
SAFETY INSTRUCTIONS
Damage to the alternator can occur if:

• Engine is operated with battery
cables disconnected.
• Battery cables are connected when
IMPORTANT using a fast charger or when
welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster
cables) are connected wrong.
I–2023–1285
1–4.3 Installing New Battery
NOTE: See Section 6 Paragraph 6–3.1 and 6–3.3 for more information on
removing and replacing batteries.
B–03709
1. Remove the negative battery cable Fig. 1–30 Removing Battery Cable
from the battery first, using a cable
puller (Fig. 1–30). Remember the
position of the battery cables so
you can connect the cables
correctly when installing the
battery.

1
2. Remove the battery holddown
(Fig. 1–31, Item 1) or (Fig. 1–32,
Item 1). Remove the battery from
the compartment.
1
3. Clean the terminal posts (Fig.
1–33) or the new battery and the
ends of the battery cables.
4. Install the new battery in the

battery compartment.
5. Install the holddown clamp.
6. Install the positive battery cable A–02835 B–05848

first and tighten. Connect the Fig. 1–31 Battery Location (540) Fig. 1–32 Battery Location (543)
negative cable last to prevent
sparks.
B–03707
Fig. 1–33 Cleaning Battery Terminals
Revised Oct. 98
540, 543 Loader
1–5 SPARK ARRESTOR MUFFLER
The spark arrestor muffler must be

cleaned every 100 hours of loader
operation.
WARNING
Stop engine and allow the
muffler to cool before cleaning
the spark chamber. Wear safety
goggles. Failure to obey can
cause serious injury.
W–2011–1285
1. Open the rear door. A–02836

Fig. 1–33 Cleaning Battery Terminals
2. Remove the plug at the bottom of
the muffler (Fig. 1–34 & 1–35).
DO NOT run the engine in an area that

has materials that can cause
WARNING

combustion. Wear safety goggles.
W–2309–0398
3. Hold a block of wood over the outlet of the muffler.
4. Start the engine and run it about 10 seconds.
5. Stop the engine and install the plug.
6. Close the rear door.
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 ar-
restor muffler to keep it in working
condition. The spark arrestor muffler
must be serviced by dumping the B–05850
spark chamber every 100 hours of op-
Fig. 1–35 Spark Arrestor Muffler (543)
eration.
If this machine is operated on flam-

IMPORTANT mable forest, brush or grass covered
land, it must be equipped with a spark
arrestor attached to the exhaust sys-
tem and maintained in working order.
Failure to do so will be in violation of
California State Law, Section 4442
PRC.
Make reference to local laws and reg-

ulations for spark arrestor require-
ments.
I–2022–0595
540, 543 Loader

28 98
SAFETY INSTRUCTIONS
1–6 HYDRAULIC/HYDROSTATIC SYSTEM
A
Be careful when repairing hydraulic/hydrostatic system.
Hydraulic pressure can drive hydraulic fluid through the
skin. Never check for leaks in a hydraulic system with
your bare hands. Use a piece of wood or piece of
cardboard [A].
If the skin is penetrated by a fluid under pressure, consult
a qualified medical service.
A–02850
Diesel fuel or hydraulic fluid under pressure

can penetrate skin or eyes, causing serious 540
injury or death. Fluid leaks under pressure may B
not be visible. Use a piece of cardboard or wood
to find leaks. Do not use your bare hand. Wear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention from a physician
familiar with this injury.
W–2072–0496

NOTE: For more information on the Hydraulic
System, see Section 2 and for more
information on the Hydrostatic System see
Section 3.
1–6.1 Replacing The Hydraulic Filter Element B–05728
The tools listed will be needed to do the following

procedure:
C 543
MEL1183 – Filter Wrench
Replace the hydraulic filter element every 100 hours of
loader operation.
To replace the filter element, use the following procedure:
Stop the engine. Open the rear door.
Clean the area around the filter housing.
Remove the filter element [B] or [C] with the filter wrench.
Clean the surface of the filter housing head where the B–05852
filter element seal contacts the filter housing.
Lubricate the rubber gasket with fluid.
Install the filter element and hand tighten only.
Operate the loader and check for leaks at the filter.
540, 543 Loader

29 of 322
SAFETY INSTRUCTIONS
1–6.2 Checking & Adding Hydraulic/Hydrostatic
Fluid A
Put the loader on a level surface, lower the lift arms and
tilt the Bob–Tach fully back. Stop the engine.
If your loader is equipped with a sight gauge, hydraulic
fluid must show in sight gauge [A] (Item 1).
1
PI–06338
If your loader is equipped with two check plugs, open the

bottom check plug on the side of the reservoir [B] (Item
B
1). The level is good if the level of fluid is between the
bottom and top check plug. If no fluid flows, close the 3
check plug.
Open the top check plug [B] (Item 2). Remove the fill cap
[B] (Item 3). Add fluid until it flows from the top check plug.
Close the check plug and install the fill cap. 2

1
If your loader is equipped with a dipstick, remove the

dipstick at the side of the reservoir [C] (Item 1). The fluid
C
level is good if the fluid level is between the top and bottom
mark on the dipstick.
540, 543 Loader

30 of 322
Revised Oct. 98 –1–13a– Service Manual
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–PreventiveMaintenanceSectionPages13a–13b
540, 543 Loader

1–6.3 Removing The
Hydraulic/Hydrostatic Fluid
The tool listed will be needed to do the
following procedure:
MEL–10627 – Transfer Pump
The hydraulic/hydrostatuc fluid must be
replaced every 1000 hours of loader
operation. Replace the hydraulic/
hydrostatic fluid more often if it becomes
dirty or after any major repairs.
NOTE: Use a hydraulic transfer B–05734

pump (Fig. 1–41) or a suction Fig. 1–40 Reservoir Filler Cap
pump (hand operated) to
remove the fluid from the
reservoir.
1. Remove the filler cap (Fig. 1–40). B–05834
Fig. 1–41 Hydraulic Transfer Pump
2. Remove the snap ring and screen from the fill pipe (Fig. 1–42). Wash the
screen in clean solvent.
3. Remove the fluid from the reservoir (Fig. 1–41). Install the screen in the fill
pipe.

4. Remove the hydraulic filter element and install a new filter element ([B] or
[C] on Page 1–13).
5. Add hydraulic/hydrostatic fluid to the reservoir (See Specifications, Section

8 for the correct fluid). Do not over–fill the reservoir.
6. Operate the loader through all the functions and then check the fluikd level
again.
1–7 FINAL DRIVE TRANSMISSION (CHAINCASE)

The chaincase is filled with the same type of fluid as the hydraulic/hydrostatic
reservoir for chain lubrication (See Specifications, Section 8 for the correct fluid).
1–7.1 Checking/Adding Chaincase Fluid
C–02602
1. Put the loader on a level surface. Stop the engine and lower the lift arms. Fig. 1–42 100 Mesh Screen
2. Remove the plug (Fig. 1–43, Item 1) at the front of the chaincase housing.
3. Add fluid through the check plug hole until the fluid flows from te check plug
hole.
4. Install the plug and tighten.
C–02037
Fig. 1–43 Chaincase Plug
540, 543 Loader

32 98
SAFETY INSTRUCTIONS
1–8 TIRE MAINTENANCE
A
Check the tires regularly for wear, damage and correct
tire pressure (See Specifications Section 8 for the correct
pressure).
1–8.1 Tire Rotation
When two tires become worn more than the other two
tires, put the two worn tires on the same side of the loader.
Rotate the tires to keep the wear even. The front tires
must be moved to the rear and the rear tires to the front
to keep the tire wear even [A].
Tires must be the same size and pressure for the best
handling of the loader, if the tires are worn different
amounts the loader durability is improved by matching C–01965R
pairs of tires on each side of the loader.
Recommended tire pressure must be maintained to avoid
loss of stability and handling capability. Tire pressure
must be checked regularly. The operating pressure are
listed under loader specifications for the recommended
tire size. Tires are sometimes inflated above or below
operating pressure for shipping, check for the correct
pressure before operating the loader.
If the tires are changed on the rims, it is important during

mounting to avoid excess pressure which can cause
rupture of the tire and serious personal injury. During
inflation of the tire, check the tire pressure frequently with
a tire pressure gauge to avoid over inflation.
Tires must not be inflated above specified

pressure to avoid explosion of the tire which
can cause serious injury.
Before the tire is mounted, the rim must be cleaned and

free of rust. Also the tire bead and rim flange must be
lubricated with a rubber lubrication before mounting the
tire on the rim to avoid damage to the tire and rim.
1–8.2 Wheel Nuts

Check the wheel nuts for correct tightness every 8 hours
during the first 20 hours of the loader operation and then
every 50 hours after that. The correct torque is shown
below:
1/2 inch studs, 55–65 ft.–lbs. (75–88 Nm) torque.
9/16 inch studs, 105–115 ft.–lbs. (142–156 Nm) torque.
DO NOT put fluid in the tires on the Bobcat

loader.

1–9 LUBRICATION OF THE
LOADER
Hydraulic Chain Case
1–9.1 Lubrication Of The Loader Reservoir
Lubricate the Bobcat loader as

specified in the SERVICE
SCHEDULE on Page 1–2 for the best
performance of the loader.
See figure 1–45 for the location of the
grease fittings.
Always use a good quality lithium
bases multi–purpose grease when B–05191
you lubricate the Bobcat loader. Fig. 1–46 Pivot Bearing Lubrication
Coolant
Apply the lubrication until the extra Grease
Transmission
grease shows. Oil Filter Grease
Lubricate the seat rails for easy
movement when adjusting the seat.
NOTE: Raise the operator cab to

lubricate some of the
grease fittings (See
Section 5 for the correct

procedure).
Lubricate the pivot bearings (Fig. 6561387 B–05197

1–46 & Fig. 1–47) every 500 hours of Fig. 1–45 Lubrication Chart Fig. 1–47 Pivot Bearing Lubrication
loader operation. Add oil as needed
to the steering control shaft (Fig.
1–48).
Add grease to the universal joints and
splines (Fig. 1–49) every 250 hours
of loader operation (543 Loader
only).
1–10 ROLL OVER PROTECTION

STRUCTURE (ROPS & FOPS)
1–10.1 Operator Cab
The Bobcat loader has an operator
cab as standard equipment. The
operator cab protects the operator
from roll over and falling objects.
B–05730 B–03371R
Fig. 1–48 Steering Shaft Lubrication Fig. 1–49 U–Joint Lubrication (543)
Revised Oct. 94
540, 543 Loader
SAFETY INSTRUCTIONS
A Nut
ROPS
Washers
Never modify the operator cab or safety
equipment or use attachments that are not
approved by Melroe Company. Modifications
or unapproved attachments can cause injury or
death.
W–2035–1285
Bushing
Fender
Bolt
Both sets of front operator cab fasteners must be Washer
assembled as shown [A]. C–02599 6565091
1–11 TRANSPORTING THE BOBCAT LOADER

B
1–11.1 Loading The Bobcat Loader
Steel ramps are available to be used to load the Bobcat
loader onto a transport vehicle.

Adequately designed ramps of sufficient
strength are needed to support the weight of B–02688
the machine when loading onto a transport
vehicle. Wood ramps can break and cause
personal injury.
W–2058–0494
A loader with empty bucket or no attachments must be

loaded backwards onto the transport vehicle [B].
1–11.2 Fastening The Loader To The Transport

Vehicle
1. Lower the bucket or attachment to the floor and stop

the engine.
2. Engage the parking brake.
3. Install the chains to hold the Bobcat loader in

position to prevent it from moving during sudden
stops or when going up or down slopes.

Put a chain through the front axle gusset and fasten the
Bobcat loader to the transport vehicle [A]. A
Fasten the chains, one in each upright cutout, to the
loader and to the transport vehicle [B].
1–11.3 Lifting The Loader
AVOID INJURY OR DEATH B–07384
* Before lifting, check fasteners on single point

lift and operator cab.
* Assemble front cab fasteners as shown in this B
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) [C] in the kit as shown in figure.
The single point lift, supplied by Melroe Company is
C–02563
designed to safely lift and support the Bobcat loader.
1–11.4 Towing The Loader
C 1
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
B–07489

SAFETY INSTRUCTIONS
1–12 LIFT ARM SUPPORT DEVICE
A
1–12.1 Installing the Approved Lift Arm Support
Device
NOTE: See Part Microfiche for the approved lift arm
support device.
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 6558015
approved lift arm support device can allow the
lift arms or attachment to fall and cause injury
or death. W–2059–0598
Two persons are needed to install or remove the

approved lift arm support device. One person must be in
the operator seat, with the seat belt fastened and seat bar
lowered, the second person is to install the approved lift
arm support device.
Start the engine and raise the lift arms all the way up.
Have the second person install the approved lift arm

support device over the rod of one of the lift cylinders [A].
Make sure the approved lift arm support device is tight
against the cylinder rod. Lower the lift arms until the
support device is held between the lift arms and the
cylinder.
Stop the engine.
Service lift arm support device if damaged or if

parts are missing. Using a damaged lift arm
support or with missing parts can cause lift
arms to drop causing injury or death.
W–2271–1197
1–13 STOPPING THE BOBCAT LOADER

When you are stopping and leaving the Bobcat loader,
use the following procedure:
Stop the Bobcat loader on level ground.
Lower the lift arms all the way down and put the edge of
the bucket on the ground.
Pull the throttle all the way backward to decrease the
engine RPM. Turn the key switch to the ‘‘OFF’’ position.
NOTE: On the 543 only, pull the stop control up.
Engage the parking brake. Lift the seat bar and
disconnect the seat belt.
Make sure the hydraulic controls are in the locked position
when the seat bar is lowered.
Remove the key from the switch to prevent operation of
the Bobcat loader by personnel other than the approved
operator.
540, 543 Loader
37 of 322
540, 543 Loader

HYDRAULIC SYSTEM
Paragraph Page
Number Number
CONTROL PEDAL, LINKAGE AND LOCKS . . . . . . . . . . . . 2–10 2–25
HYDRAULIC
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . 2–3 2–3 SYSTEM
HYDRAULIC CONTROL VALVE (MELROE) . . . . . . . . . . . . 2–3A 2–10

HYDRAULIC/HYDROSTATIC RESERVOIR . . . . . . . . . . . . . . 2–7 2–22
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 2–10i

HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . 2–2 2–2
LIFT CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5 2–15
10 MICRON FILTER BY–PASS VALVE . . . . . . . . . . . . . . . . . . 2–9 2–24

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 2–23
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6 2–20

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 2–1
Avoid contact with leaking hydraulic

fluid which under pressure can be
forced through the skin. Never check
WARNING for leaks in a hydraulic system with
your bare hands. Use a piece of
wood or cardboard. If your skin is
penetrated by a fluid under pressure
consult a qualified medical service.

without instructions or taking the A–02850
the warnings and instructions at the
WARNING beginning of this Service Manual.
death.

540, 543 Loader

41 of 322
42 of 322
43 of 322
44 of 322
45 of 322
46 of 322
47 of 322
48 of 322
HYDRAULIC SYSTEM
2–1 TROUBLESHOOTING
The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 4

Slow hydraulic system action. 1, 3, 5, 6, 7
Hydraulic action is not smooth. 1, 5, 6, 7, 8
Lift arms go up slowly at full engine RPM. 1, 3, 5, 6, 7, 9, 11
The lift arms or Bob–Tach will move with the pedal in neutral position. 5, 10
The lift arms come down slowly with the pedal in the neutral position. 5, 10, 11, 12, 13

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

2. The pedal linkage is disconnected.
3. The hydraulic pump is not working correctly.
4. The relief valve is not working correctly.
5. The pedal lock linkage is not adjusted correctly.
6. Relief valve is not at the correct pressure.
7. Suction leak on the inlet side of the hydraulic pump.
8. Fluid is cold.
9. Using the loader for more than its rated capacity.
10. Spool in the valve section is not centering or the centering spring is broken.
11. Internal leak at the lift cylinder(s).
12. External leak at the lift cylinder(s).
13. Excess control valve leakage.
540, 543 Loader

2–2 HYDRAULIC SYSTEM INFORMATION
Mark A Line On Nut

Flats Of Both Nuts
When making repairs on hydraulic
system, keep all parts clean and
IMPORTANT remove all dirt from the area before
you begin disassembly. Use caps
and plugs to keep dirt out of
tubelines and openings.
Tighten To Correct
Amount From Chart
2–2.1 37° Flare Connections
Use the following procedure to tighten the flare fittings:
1. Tighten the nut until it makes contact with the seat.
2. Make a mark across the flats of both the male and female parts of the A–01897
connection (Fig. 2–1). Fig. 2–1 Tightening Flare Fittings
3. Use the chart below to find the correct tightness needed.
Tube Size Rotate No. of

Wrench Size Outside Diameter Thread Size Hex Flats

5/8 inch 5/16 inch 1/2 – 20 2–1/2
11/16 inch 3/8 inch 9/16 – 18 2
7/8 inch 1/2 inch 3/4 – 16 2
1 inch 5/8 inch 7/8 – 14 1–1/2 – 2
1–1/4 inch 3/4 inch 1–1/16 – 12 1
1–3/8 inch 1 inch 1–5/16 – 12 3/4 – 1
2 inch 1–1/4 inch 1–5/8 – 12 3/4 –1
2–1/4 inch 1–1/2 inch 1–7/8 – 12 1/2 – 3/4
Nut
If the fitting leaks after tightening, disconnect it and inspect it and inspect the seat
area for damage. Replace as needed.
Washer
2–2.2 Straight Thread O–Ring Fitting O–Ring

When installing this fitting, the O–ring must be first lubricated with grease. Loosen
the jam nut, turn the fitting into place and connect the tubeline, then tighten the
jam nut.
Tighten the jam nut until it and the washer are tight against the surface (Fig. 2–2).
The O–ring must be pushed into the space as shown.
2–2.3 Tubelines And Hoses

Nut
Make replacement of tubelines which are bent or have become flat. There will be
a restriction of fluid flow, which will make for slow hydraulic action and cause heat.
Make replacement of hoses which show signs of wear, damage or weather Washer
cracked rubber.
When installing tubelines or hoses, make sure you use two wrenches when O–Ring
tightening them.
A–01852
Fig. 2–2 Straight Thread Seal
540, 543 Loader

2–3 HYDRAULIC CONTROL VALVE
When making repairs on hydraulic system,

keep all parts clean and remove all dirt from the
area before you begin disassembly. Use caps
and plugs to keep dirt out of tubelines and
openings.
Wear in the control valve or spool will cause the hydraulic

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

keep the spool in the neutral position.
(b) Check for leaks in the valve because of wear
or cracked valve body.
2–3.1 Relief Valve
Never work on a machine with the lift arms up Put jackstands under the front axles and rear
unless the lift arms are secured by a lift arm corners of the frame before running the engine
support device. Failure to use an approved lift for service. Failure to use jackstands can allow
arm support device can allow the lift arms or the machine to fall or move and cause injury or
attachment to fall and cause injury or death. death.
W–2059–0991 W–2017–0286

procedure:
MEL10003 – Hydraulic Tester
MEL10006 – Hydraulic Test Kit
Check The Relief Valve
Operate the loader until the fluid is at operating
temperature (120–140°F [48–60°C]).
When the engine is running during service, the
Stop the engine. steering levers must be in neutral and the
parking brake engaged. Failure to do so can
Activate the auxiliary hydraulic control (right steering cause injury or death.
lever) to release the hydraulic pressure. W–2006–0284
Revised Oct. 94
540, 543 Loader

Connect the hydraulic tester to the auxiliary quick
couplers [A]. A
The hydraulic tester must be in the fully open

position before you start the engine.
I–2024–0284
Start the engine and run at idle RPM. Engage the auxiliary B–06429
hydraulics into the detent position by moving the right
steering lever to the right.
Watch the flow meter on the hydraulic tester to make sure
B
the flow is correct.
Increase the engine speed to full RPM.
There should be 8.0 GPM (30,1 L/min.) free flow.
Turn the restrictor control, on the tester, until the main

relief valve opens. The correct pressure for the main relief
valve is 1575–1675 PSI (10860–11548 kPa).
Removal Of The Relief Valve

Stop the engine. B–07379
Activate the hydraulic controls to release the hydraulic

pressure.
C
Raise the operator cab (See Paragraph 5–1.1, Page
5–1).
Clean the control valve area.
Remove the plug for the relief valve [C].
You may have to use a magnet to remove the poppet from
the control valve.
Clean and inspect the relief valves parts.
The shims (Item 1) [D] can be added or removed to get

the correct pressure. Each 0.010 inch (0,254 mm) shim B–05297
will increase or decrease the pressure 100 PSI (670 kPa).
NOTE: Do not use more than 0.040 inch (1,01 mm)

D
thickness of shims.
Installation Of The Relief Valve

1
Install a new O–ring on the plug for the relief valve.
Install the seat, poppet, spring, shims and plug in the
correct order [D] or damage can occur to the hydraulic
pump.
Check the hydraulic pressure again using the above
procedure. If the pressure is not correct, add or remove
the shims (Item 1) [D]. B–05313

Lower the operator cab. (See
Paragraph 5–1.2, Page 5–1a.)
Remove the hydraulic tester and the
jackstands from under the loader
frame.
B–05340 B–05301
2–3.2 Removal Of The Hydraulic Fig. 2–6 Removing Hose Fig. 2–7 Valve Tilt Linkage
Control Valve
Lift the loader and put

jackstands under the frame so
there is no danger of the loader

falling and causing personal
injury.
B–05309 B–05302
Fig. 2–8 Valve Auxiliary Linkage Fig. 2–9 Auxiliary Linkage
1. Stop the engine.
2. Activate all the hydraulic controls to release the hydraulic pressure.
3. Raise the operator cab. (See Paragraph 5–1.1, Page 5–1.)
4. Remove the hydraulic/hydrostatic fluid from the reservoir. (See Paragraph

1–6.3, Page 1–14.)
5. Clean the area around the control valve. Always use caps or plugs when
removing hoses or tubelines.
6. Remove the hose from the control valve (Fig. 2–6) which goes to the port
block. B–05300
Fig. 2–10 Valve Lift Linkage
7. Disconnect the tilt linkage from the control valve (Fig.2–7).
8. Loosen the lock nut at the auxiliary control rod at the steering levers (Fig.
2–8) so the linkage can be turned when it is removed from the valve.
9. Remove the hair pin and pin at the auxiliary linkage at the control valve
(Fig.2–9) and remove the linkage from the control valve.
10. Disconnect the lift linkage at the control valve (Fig. 2–10).
11. Disconnect all the tubelines from the control valve (Fig. 2–11).
12. Remove the tire and wheel assembly at the right rear of the loader.
B–05259
Fig. 2–11 Disconnecting The Tubelines
13. Remove the two bolts from the
control valve (Fig. 2–12).
14. Remove the hydraulic control

valve from the loader (Fig.
2–13).
2–3.3 Disassembly Of The

Hydraulic Control Valve
The tools listed will be needed to do
B–05314 B–05298
MEL1074 – O–ring Seal Hook Fig. 2–12 Removing Valve Bolts Fig. 2–13 Removing The Control Valve
MEL1190 – Magnet
1. Clean the control valve before

disassembly.

Mark each spool before
disassembly so they will go
back to their original bore.
B–05312 B–05277
Fig. 2–14 Lift Section Orifice Fig. 2–15 Auxiliary End Cap
2. Remove the orifice from the lift
section of the control valve (Fig.
2–14).
3. Put the control valve in the vise.
4. Loosen the auxiliary section

end cap (Fig. 2–15).
5. Remove the auxiliary section

spool (Fig. 2–16).
6. Loosen the lift section end cap

(Fig. 2–17).
B–05275 B–05268
7. Remove the lift section spool Fig. 2–16 Auxiliary Spool Fig. 2–17 Lift End Cap
(Fig. 2–18).
8. Loosen the tilt section end cap

(Fig. 2–19).
B–05276 B–05278
Fig. 2–18 Lift Spool Fig. 2–19 Tilt End Cap
540, 543 Loader

9. Remove the tilt section spool
(Fig. 2–26).
10. Remove the O–rings from the

B–05274 B–05263
Fig. 2–20 Tilt Spool Fig. 2–21 Control Valve O–rings
11. Loosen the end cap for the relief

valve (Fig. 2–22).
12. Remove the end cap and spring

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

B–05267 B–05266
Fig. 2–22 Relief Valve End Cap Fig. 2–23 Relief Valve Spring
13. Use a magnet and remove the

relief valve poppet from the
bore (Fig. 2–24).
14. Use the special tool and

remove the seat from the
B–05265 B–05264
Fig. 2–24 Relief Valve Poppet Fig. 2–25 Relief Valve Seat
15. If the detent mechanism is not

disassembled, remove the
O–ring over the valve spool
lands (Fig. 2–26).
2–3.4 Detent Mechanism
NOTE: Only disassemble the

detent mechanism if it is
damaged or parts are
broken.
B–05270
Fig. 2–26 O–ring On The Spool
540, 543 Loader

1. To disassemble the detent
mechanism, wrap cloth around
the end cap and valve spool
(Fig. 2–27). Pull the end cap off
the valve spool. Be careful not
to lose the balls from the detent
when removing the cloth from
the spool.
B–05287
Fig. 2–27 Removing End Cap From Spool
2. Remove the end cap from the

detent bolt. Using a punch,
loosen the detent bolt (Fig.
2–28) through the hole in the
detent bolt.
3. Remove the detent bolt, spring

and seat from the spool (Fig.
2–29).

B–05272 B–05286
Fig. 2–28 Detent Bolt Fig. 2–29 Detent Mechanism Assembly
4. The detent bolt for the lift spool

has an O–ring installed at the
end of the detent bolt (Fig.
2–30). Install a new O–ring
before installing the bolt.
5. Install a new O–ring on the

spool before assembling the
detent mechanism.
6. When installing the detent

spring and balls, use the
following procedure:
B–05285 B–05284
(a) Install the spring in the hole
of the detent bolt. Fig. 2–30 Detent Bolt O–ring Fig. 2–31 Detent Spring And Ball
(b) Put grease on the ends of

the spring and put the balls on
the ends of the springs (Fig.
2–31).
(c) Push the end cap over the
balls until they seat inside the
2–3.5 Assembling The Hydraulic

Control Valve
1. If the detent mechanism was

not removed, carefully install a
new O–ring over the three valve B–05308 B–05270
spools (Fig. 2–33). Fig. 2–32 Installing End Cap Fig. 2–33 Installing The O–ring
540, 543 Loader

2. Install new O–rings in the three
bores for the spools in the
3. Carefully install all three spools

in their correct locations (Fig.
2–35).
B–05263 B–05274
Fig. 2–34 Installing The O–rings Fig. 2–35 Installing Spools
4. Tighten the end caps of the

valve spools (Fig. 2–36).
5. Install the seat for the relief

valve, using the special tool
(Fig. 2–37) and tighten.
6. Install the poppet.

B–05277 B–05264
Fig. 2–36 Tighten The End Caps Fig. 2–37 Installing Relief Valve Seat
7. Install the spring and the end

cap (Fig. 2–38). Make sure all
the shims are in the end cap.
Tighten the end cap.
8. Install the orifice in the lift

section port of the control valve
(Fig. 2–39).
B–05266 B–05312
Fig. 2–38 Installing Relief Valve Fig. 2–39 Installing The Orifice
9. Remove the plug (Fig. 2–40)

and check the poppet and seat
of the load check valves (Fig.
2–41). Replace parts as
needed.
NOTE: Move the spool in and out

in the control valve bore. If
it sticks, rotate it 180° and
try again.
B–05294 B–05290
Fig. 2–40 Load Check Plug Fig. 2–41 Load Check Poppet
540, 543 Loader

2–3.6 Installing The Hydraulic
Control Valve
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–HydraulicSystemSectionPages1–10
1. Install the control valve in the

loader (Fig. 2–42).
2. Install the two bolts in the

control valve (Fig. 2–43) and
tighten to 11–13 ft.–lbs. (15–18
Nm) torque.
B–05298 B–05314
Fig. 2–42 Installing The Control Valve Fig. 2–43 Installing The Bolts
3. Connect all the tubelines to the

4. Connect the auxiliary linkage at

the steering lever (Fig. 2–45).
Adjust the linkage so the valve
spool does not move when the
steering lever is moved.

B–05259 B–05309
Fig. 2–44 Connecting Tubelines Fig. 2–45 Connecting Linkage
5. Connect all the linkages at the

6. Connect the hydraulic hoses to

the control valve and tighten
(Fig. 2–47).
7. Add the correct fluid to the

hydraulic/hydrostatic reservoir
(See Section 8 for the correct
fluid).
B–05302
Fig. 2–46 Connecting Linkage
8. Install the tire and wheel

assembly.
9. Lower the operator cab (See

Paragraph 5–1.2, Page 5–1a).
10. Remove the jackstands from

under the loader frame.
B–05340
Fig. 2–47 Installing Hoses
540, 543 Loader

Revised Oct. 94
2–3A HYDRAULIC CONTROL VALVE (MELROE)
When making repairs on hydraulic

system, clean the work area before
disassemble and keep all parts clean.
IMPORTANT Always use caps and plugs on hoses,
tubelines and ports to keep dirt out.
Dirt can quickly damage the system.
I–2056–0793
Wear in the control valve or spools will cause the hydraulic cylinders to move when
the controls are in the neutral position. Wear can also cause loss of hydraulic
power.
To find an internal leak in the control valve, first check the condition of the cylinder
(See Paragraph 2–5 or 2–6). If the lift arm or tilt cylinder still move or extend after
the cylinders are checked to be good then check the control valve for the following:
1. Spool not centering in the valve section when the pedal is released. The
spring can be broken or check the pedal linkage and adjust it so it will keep
the spool in the neutral position.
2. Check for leaks in the valve because of wear or cracked valve body.
2–3A.1 Relief Valve

Never work on a machine with the lift
arms up unless the lift arms are
secured by an approved lift arm
WARNING support device. Failure to use an
approved lift arm support device can
allow the lift arms or attachment to
fall and cause injury or death.
W–2059–0598
The tools listed will be needed to do the following procedure:

MEL10003 – Hydraulic Tester
MEL10006 – Hydraulic Test Kit
Loader must be restrained for some

service and repair. When balance of
loader is changed by removal of lift
arms or engine, or when it is
necessary to rotate axles,
WARNING jackstands should be put under both
front axles and both rear corners of
frame. Blocks by wheels can be
climbed and do not stop loader.
W–2310–0398
Check The Relief Valve
1. Operate the loader until the fluid is at operating temperature.
2. Stop the engine.
540, 543 Loader

59 of 322
Revised Oct. 98 –2–10a– Service Manual
3. Connect the tester to the quick
couplers (Fig. 2–48a).
IMPORTANT
The hydraulic tester must be in
the fully open position before
you start the engine.
I–2024–0284
4. Start the engine and run at idle

RPM.
5. Activate the auxiliary hydraulic

control (right steering lever) to put B–06429
pressure into the hydraulic tester
(inlet). Watch the flow on the Fig. 2–48a Checking The Relief Valve
hydraulic tester. Increase the
engine RPM.
6. Turn the restrictor control on the tester to increase the pressure.
7. Read the pressure gauge. The pressure must be 1575–1675 PSI

(10869–11548 kPa).
Adjusting The Relief Valve
1. Stop the engine. Raise the operator cab.
2. Clean the area around the control valve.
NOTE: The main relief valve does not have to be removed from the control
valve to be adjusted.
1
3. Remove the cap from the relief valve (Fig. 2–49a, Item 1).
4. Using an allen wrench adjust the relief valve (Fig. 2–50a), turn clockwise to
increase the pressure. Turn counterclockwise to decrease the pressure.
5. Check the hydraulic pressure again using the above procedure. If the
pressure is not correct, adjust the relief valve until the pressure is correct.
6. Install and tighten the cap on the main relief valve.

B–09894
7. Lower the operator cab. Fig. 2–49a Main Relief Valve
Relief Valve Service

The most common cause of relief cartridge failures is dirt in the hydraulic fluid,
which lodges in the working parts and interferes with the operation. The cartridges
can be cleaned without changing the setting. Check and clean a malfunctioning
cartridge as follows:
1. Remove the cartridge from the control valve (Fig. 2–49a).
B–09893
Fig. 2–50a Adjusting The Relief Valve
540, 543 Loader

60 98
Revised Oct. of 322 –2–10b– Service Manual
2. Inspect for visible contaminants and carefully remove obvious particles.
3. Through the nose of the cartridge, manually operate the inner working parts
several times with cartridge submerged in clean mineral spirits. Use a
wooden or plastic dowel to avoid damaging the soft seats, sharp edges or
finished surfaces. All parts must move freely.
4. After flushing the cartridge, blow dry with clean filtered air.
5. Replace the seals with new seals.
6. Install the cartridge and tighten to 35–40 ft.–lbs. (47–54 Nm) torque.
The main relief valve should not be replaced unless the above procedure, plus
adjustment attempt, fails to resolve the problem.
Installation Of A New Relief Valve
1. Raise the operator cab.
2. Loosen the relief valve and remove from the control valve.
3. Install a new O–ring on the new relief valve.

4. Install the relief valve and tighten to 35–40 ft.–lbs. (47–54 Nm) torque.
2–3A.2 Removal Of The Hydraulic Control Valve (Melroe)
1. Stop the engine.
2. Activate all the hydraulic controls to release the hydraulic pressure.
3. Raise the operator cab. (See Paragraph 5–1.1, Page 5–1.)
4. Clean the area around the control valve. Always use caps or plugs when
removing hoses or tubelines.
5. Remove the hoses from the control valve.
6. Disconnect the linkages from the valve spools.
7. Disconnect all the tubelines from the control valve.
8. Remove the two bolts and nuts from the control valve.
9. Remove the control valve from the loader.

61 of 322 –2–10c– Service Manual
2–3A.3 Disassembly Of The Control Valve
1
When making repairs on the

hydraulic control valve, keep all
IMPORTANT parts clean and remove all the dirt
from the control valve.
B–05833
Fig. 2–51a Load Check Valves
To disassemble the hydraulic control

valve, use the following procedure: A1 – Lift Cylinder, Rod End
A2 – Tilt Cylinder, Rod End
(Internal Restrictor 0.109”)
1. Mark each section and spool of A3 – Auxiliary Coupler
the control valve so that each B1 – Lift Cylinder, Base End
spool can be returned to its (Internal Restrictor 0.125”)
original bore during assembly. B2 – Tilt Cylinder, Base End
B3 – Auxiliary Coupler
C1 – Lift Load Check

2. Put the control valve on a work
bench and install bolts through C2 – Tilt Load Check
the valve and bench for easier C3 – Auxiliary Load Check
disassembly. D1 – Lift Spool
D2 – Tilt Spool
D3 – Auxiliary Spool
3. Remove the load check valves E1 – Plug
(Fig. 2–51a, Item 1) from the F1 – Relief Valve
three center ports (Fig. 2–52a, F2 – Anti–Cav. Valve
Items C1, C2 & C3) in the top G1 – Lift Detent
section of the control valve. G2 – Tilt Centering Spring
G3 – Auxiliary Detent
Inlet Outlet
B–06288
Fig. 2–52a Control Valve Layout
4. Remove the anti–cavitation 1. Plug 1. Anti–Cavitation Check

valve (Fig. 2–52a, Item F2) 2. O–ring 2. O–ring
from the center port. Remove 3. Back–up Washer 3. Back–up Washer
the O–rings and back–up 4. O–ring 4. O–ring
washers (Fig. 2–53a) from the
anti–cavitation valve.
5. Remove the plug (Fig. 2–52a,

Item E1) from the other side of
the valve center port. Remove 4 1
the O–rings and back–up 3
washer (Fig. 2–54a). 2 2
1 3
4
E–01446 E–01446
Fig. 2–53a Anti–Cavitation Valve Fig. 2–54a Plug

62 of 322 –2–10d– Service Manual
6. Remove the relief valve (Fig.
2–55a) from the control valve. 1. O–ring
Remove the O–rings and 2. Back–up Washer
back–up washers from the 3. Back–up Washer
relief valve (Fig. 2–55a). 4. O–ring
5. Main Relief Valve
1 2 3 4 5
B–06444 E–01446
Fig. 2–55a Main Relief Valve
7. Loosen the screws which

fasten the rubber boots to the
lower section of the control
valve (Fig. 2–56a).
4 3 2
8. Remove the bolts (Fig. 2–57a,
Item 1), rubber boots (Item 2),
boot retainer (Item 3) and filter
(Item 4) from each of the three
valve spools (Fig. 2–52a, Items

D1, D2 & D3).
1
B–06445 B–05804
Fig. 2–56a Rubber Boot Screw Fig. 2–57a Rubber Boot Assembly
9. Using an O–ring tool, remove

the O–rings from each of the
three spools (Fig. 2–58a).
10. Remove the detent snap ring on

the lift section end cap (Fig.
2–59a) and washer.
11. Remove the bolts which fasten

the detent cap to the control
valve (Fig. 2–60a).
B–06446 B–06447
12. Remove the detent cap from
the lift spool. Fig. 2–58a Removing O–rings Fig. 2–59a Detent Snap Ring
Be careful: do not lose the

detent balls. There are four
balls and two springs.
13. Remove the detent sleeve.

Remove the balls and spring
(Fig. 2–61a) from the detent B–06448 B–06449
adapter. Fig. 2–60a Detent End Cap Bolts Fig. 2–61a Detent Balls And Spring
63 of 322 –2–10e– Service Manual
14. Using an allen wrench, remove the adapter which holds the centering spring
to the lift spool (Fig. 2–62a).
Carefully remove the bolt from the

spool because there is spring
IMPORTANT tension.
15. Remove the spool from the control valve.
16. Remove the back–up washer (Fig. 2–63a) and O–ring.

B–06450
Fig. 2–62a Centering Spring Bolt
Handle the valve spool with care. Do
not damage the spool surface. Make
IMPORTANT sure to mark each spool so they will
be returned to their original bore
when the control valve is assembled.
17. Remove the bolts from the end cap at the tilt spool (Fig. 2–64a).
18. Remove the end cap.

19. Using an allen wrench, remove the bolt which holds the centering spring to
the tilt spool (Fig. 2–65a).
20. Remove the bolt, spring, back–up washer and O–ring (Fig. 2–66a).
B–06451
Fig. 2–63a Back–up Washer
21. Remove the tilt spool from the
control valve.
22. Repeat steps 13 thru 16 for the

auxiliary section detent and
spool.
2–3A.4 Inspection Of The Control

Valve
1. Check the spools for scratches

or wear.
2. Check that the spools are not

loose in their bores. If they are
B–06286
loose there may be damage or
wear to the control valve block. Fig. 2–64a End Cap Bolts
3. Check that the centering

springs are not broken.
4. Check that the load check seats

are not worn.
5. Check that the load check

poppets are not worn
6. Check that the rubber boots,

boot retainers and filters are not
worn.
7. Replace any parts that are worn

or broken. B–06285 B–06284
Fig. 2–65a Centering Spring Bolt Fig. 2–66a Centering Spring Assembly

64 of 322 –2–10f– Service Manual
2–3A.5 Assembly Of The Control Valve
2
MEL1278 – Detent Tool
1. Install the detent tool in the vise (Fig. 2–67a, Item 1).
2. Install the detent adapter (Fig. 2–68a, Item 1) into the detent tool. Make
alignment with the holes in the tool and the holes in the adapter.
3. Install the ball, spring and ball into the tool and adapter (Fig. 2–69a).
1
4. Turn the bolt into the tool to hold the balls and spring in position. B–06452
Fig. 2–67a Detent Tool
5. Put grease in the spring end of the cap. Install the spring end cap (Fig. 2–68a,
Item 2) on the adapter (Fig. 2–70a) in the correct position. Remove the
detent tool.
6. Put oil on the O–ring (Fig. 2–68a,
Item 3) and install it on the spool. 5
4
7. Put the spool in the vise and hold
it at the linkage end of the spool.
NOTE: (Lift spool only) Be sure

plastic plug is in the spool

bore.
8. Install the adapter stud (Fig. 3 2 1

2–68a, Item 4). Leave .60’’ (15
E–01446
mm) exposed for the adapter.
Fig. 2–68a Lift & Auxiliary Detent Assembly
9. Install the back–up washer, spring
end cap, spring and the detent
adapter on the spool. Tighten the
adapter to 90–100 in.–lbs. (10–11
Nm) torque.
10. Install the detent tool (Fig. 2–71a,

Item 1) on the adapter.
11. Install the balls and spring into the

tool and the adapter (Fig. 2–71a).
Turn the bolt into the tool to hold
the balls and spring in the correct
position.
B–06454
Fig. 2–69a Installing Springs & Bolts
B–06455 B–06456
Fig. 2–70a Installing Adapter Fig. 2–71a Detent Tool
540, 543 Loader

65 of 322
Revised Oct. 98 –2–10g– Service Manual
12. Put grease into the detent sleeve. Install the detent sleeve (Fig. 2–68A, Item
5) on the adapter and pull the tool away and push the sleeve into position
(Fig. 2–72a).
NOTE: Lift detent sleeve is deeper.
13. Remove the spool from the vise. Put oil on the spool. Carefully install the
spool in the auxiliary section of the control valve.
14. Install the detent end cap.
15. Install the bolts. Tighten the bolts to 90–100 in–lbs. (10–11 Nm) torque.
16. Install the washer and snap ring on the detent sleeve (Fig. 2–73a). A–02844
Fig. 2–72a Installing Detent Sleeve
17. Put oil on the O–ring (Fig. 2–74a, Item 1). Install the O–ring on the tilt spool.
18. Put oil on the tilt spool. Carefully install it in the tilt section of the control valve.
19. Install the back–up washer (Fig. 2–74a, Item 2), end cap (Item 3), centering
spring (Item 4), end cap (Item 5) and adapter (Item 6).
20. Put LOCTITE on the bolt (Fig. 2–74a, Item 7). Install and tighten the bolt to
90–100 in.–lbs. (10–11 Nm) torque.
21. Install the end cap.

22. Install the end cap bolts Tighten the bolts to 90–100 in.–lbs. (10–11 Nm)
torque.
23. Repeat steps 1 thru 16 to install the detent assembly and the lift spool into B–06447
the control valve. Fig. 2–73a Detent Sleeve Snap Ring
24. Install the back–up washer, filter,
O–ring, boot and boot retainer on
each of the three spools (Fig. 2 3 4 5
2–75a). 1 6 7
25. Install the bolts for the boot

retainers. Tighten the bolts to
90–100 in.–lbs. (10–11 Nm)
torque on each of the three spools.
Check all three spools for correct
function and detent.
26. Install the main relief valve.

Tighten to 35–40 ft.–lbs. (47–54
Nm) torque.
E–01446
27. Install the plug, with new O–rings Fig. 2–74a Tilt Centering Spring Assembly
and back–up washers, into the tilt
section port (Fig. 2–52a, Item E1).
B–05804
Fig. 2–75a Rubber Boot & Retainer
540, 543 Loader

66 98
Revised Oct. of 322 –2–10h– Service Manual
28. Tighten the plug to 35–40 ft.–lbs. (47–54 Nm) torque.
29. Install the anti–cavitation valve, with new O–rings and back–up washers,
into the tilt section port (Fig. 2–52a, Item F2).
30. Tighten the anti–cavitation valve to 35–40 ft.–lbs. (47–54 Nm) torque.
31. Install the load check valves into the top section of the control valve (Fig.
2–52a, Items C1, C2 & C3). Use new O–rings and back–up washers.
32. Tighten the load check valves to 35–40 ft.–lbs. (47–54 Nm) torque.
2–3A.6 Installation Of The Control Valve
1. Install the control valve into the loader.
2. Install the two mounting bolts. Tighten the mounting bolts to 180–200 in.–lbs.
(21–23 Nm) torque only.
NOTE: Check operation of valve spool, if sticking, rotate the spool 180° and
a smoother operation may be the result.
3. Connect the linkages to the spools of the control valve.

4. Connect the tubelines to the valve and tighten.
5. Connect the hoses to the valve and tighten.
6. Add the correct fluid to the hydraulic/hydrostatic reservoir (See Section 8 for
the correct fluid).
7. Lower the operator cab (See Paragraph 5–1.2, Page 5–1a).
8. Operate the loader through the hydraulic functions. Stop the engine. Check
for leaks. Check the reservoir and add fluid as needed.
2–4 HYDRAULIC PUMP
Lift the loader and put jackstands

under the frame so there is no
WARNING danger of the loader falling and
causing personal injury.
Be careful when turning the flow

control valve. When the tester is
WARNING connected this way, there is no relief
valve in the system. DO NOT close
the valve (on the tester) all the way.

67 of 322 –2–10i– Service Manual
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–HydraulicSystemSectionPages10a–10j
540, 543 Loader

68 of 322 –2–10j– Service Manual
2–4.1 Checking Output Of Hydraulic Pump
A
This test will determine the acceptable flow of the
hydraulic pump. A hydraulic tester is required that will
measure flow, temperature and pressure.
2
NOTE: Make sure that all the air is removed from the
system before beginning the test. Air in the
system can give an inaccurate test.
Stop the engine. 3

1
Raise the operator cab. (See Paragraph 5–11, Page 5–1.)
Disconnect the hose from the outlet of the hydraulic pump
and connect it to the inlet (Item 1) [A] of the tester. P–03739
Connect the hose from the OUTLET of the hydraulic

pump (Item 2) [A] to the INLET (Item 3) [A] of the tester. B
NOTE: Make sure that the restrictor valve (Item 1) [B]
on the tester is fully open.
Start the engine and run at low RPM. If no flow is indicated

on the tester, the hoses are connected backwards.

NOTE: See Paragraph 5–1.3, Page 5–1b for the
correct procedure to start the engine.
Increase the engine RPM to full RPM.*

1
Warm the hydraulic fluid to 140°F (60°C) by turning the P–03738
restrictor knob on the tester to about 1000 PSI (6895
kPa). Do not exceed system relief pressure.
Open the restrictor on the tester and record the free flow
C
(GPM) at full RPM.
Disconnect any attachment from the auxiliary quick 1
couplers and operate the auxiliary control lever. Record
the high pressure (PSI) and the flow (GPM) at full RPM.
The high pressure flow must be at least 80% of free flow.
HIGH PRESSURE FLOW (GPM)

%= x 100
FREE FLOW (GPM)
2
A low percentage may indicate a failed hydraulic pump, P–03740
or air in the system. Make sure that all air is removed from
the system.
* Make reference to your Model loader, in the Technical
Service Guide, for the system relief pressure and full
RPM specifications. The system relief pressure must be
per specification before the test is run.
2–4.2 Removal Of The Hydraulic Pump When making repairs on the hydraulic system,
keep all parts clean and remove the dirt from
Remove the hydraulic/hydrostatic fluid from the reservoir. the area. Use caps and plugs to keep debris out
(See Paragraph 1–6.3, Page 1–4.) of the tubelines or ports.
Remove the front panel.
Remove the inlet hose (Item 1) [C] and outlet hose (Item
2) [C] from the hydraulic pump.

1. Remove the two bolts which
hold the hydraulic pump to the
hydrostatic pump (Fig. 2–51).
2. Remove the hydraulic pump

from the hydrostatic pump (Fig.
2–52).
3. Remove the hydraulic pump

coupler (Fig. 2–53).
4. Remove the O–ring from the

hydraulic pump mounting area.
B–05933 B–05934
Fig. 2–51 Removing Pump Bolts Fig. 2–52 Removing The Pump

Hydraulic Pump
1. Put the pump in a vise.
2. Put a mark across the housing

of the pump for correct
assembly (Fig. 2–54).

B–05936 B–05937
Fig. 2–53 Removing The Pump Coupler Fig. 2–54 Marking The Pump Housing
3. Loosen and remove the four

bolts on the pump (Fig. 2–55).
4. Remove the pump from the

vise. Hold the pump in both
hands and hit the shaft against
a block of wood to separate the
pump housing (Fig. 2–56).
B–05938 B–05940
Fig. 2–55 Removing Pump Bolts Fig. 2–56 Separating Pump Housing
5. Remove the pump end housing

(Fig. 2–57).
6. Remove the pump gears (Fig.

2–58).
7. Remove the wear plate (Fig.

2–59, Item 1).
B–05945 B–05946
Fig. 2–57 Removing End Housing Fig. 2–58 Removing Pump Gears
540, 543 Loader

8. Remove the gasket and
diaphragm seal from the pump 1
housing (Fig. 2–59, Item 2).
9. Remove the spring and steel

ball from the housing (Fig.
2–60).
NOTE: Make sure to mark the port

where the spring and ball 2
are removed. B–05947 B–05950
Fig. 2–59 Pump Wear Plate Fig. 2–60 Spring And Ball
2–4.4 Inspection Of The Hydraulic
Pump
2
1. Clean and dry all the parts.
2. Inspect the drive gears

(Fig.2–61).
3. Inspect both drive gear and

idler gear shafts at the bearing

points and seal area for rough
surfaces and wear.
4. Check the face of the gears for 1

wear. B–04426 B–05947
Fig. 2–61 Gear Inspection Fig. 2–62 Installing Wear Plate
5. Check the wear on the face of
the wear plate. If the wear is
more than 0.0015 inch (0,038
mm) from one side to the other,
the plate must be replaced.
6. Check the housing gear area

for wear.
2–4.5 Assembling The Hydraulic Pump
1. The diaphragm seal and gasket must be replaced when assembling the
pump (Fig. 2–62, Item 1).
B–05950
If the ball and spring are not installed
in the correct port, damage will Fig. 2–63 Installing Ball And Spring
result to the complete hydrostatic
pumps. Only one ball and spring
IMPORTANT must be installed on the high
pressure side of the pump or the
lower port as it attached to the
hydrostatic pumps.
2. Put the spring and steel ball in the port that was marked on disassembly (Fig.
2–63). This must be the pressure side of the pump.
3. Install the wear plate. (Fig. 2–62, Item 2.)
4. Install the pump gears. (Fig. 2–64.)

B–05946
Fig. 2–64 Installing The Pump Gears
540, 543 Loader

5. Install the pump end housing. (Fig. 2–65.)
6. Install the four bolts (Fig. 2–66) and tighten to 25–28 ft.–lbs. (34–38 Nm)
torque (Dry Threads).
7. Rotate the pump shaft, the pump will have some amount of resistance but
will turn freely.
2–4.5 Installation To The Hydraulic Pump
1. Install the hydraulic pump coupler (Fig. 2–67).
2. Install a new O–ring on the hydraulic pump housing.

B–05945
3. Install the pump on the hydrostatic pump (Fig. 2–68). Fig. 2–65 Installing End Housing
4. Install the bolts and tighten (Fig. 2–68).
5. Install the hoses and tighten.
6. Install the front panel.
7. Go to paragraph 2–4.6 for the correct start–up procedure.

2–4.6 Start–up Procedure For The Hydraulic Pump B–05938
Fig. 2–66 Installing Pump Bolts
1. Add fluid to the hydraulic/hydrostatic reservoir (See Section 8 for the correct
fluid).

under the frame so there is no
2. Start the engine and run it at half RPM with no hydraulics engaged for several
minutes.
B–05936
3. Operate the hydraulic control valve. Build up pressure at three second Fig. 2–67 Installing Pump Coupler
intervals for several minutes.
4. Increase the engine speed to

full RPM and repeat step 3.
5. Slow the engine to idle RPM

and stop the engine. Check for
leaks.
6. Check the hydraulic/

hydrostatic reservoir. Add fluid
as needed.
7. Lower the operator cab. (See

Paragraph 5–1.2, Page 5–1).
8. Remove the jackstands from B–05934 B–05933

under the loader frame. Fig. 2–68 Installing Hydraulic Pump Fig. 2–69 Tighten Pump Bolts

2–5 LIFT CYLINDERS
2–5.1 Checking The Lift Cylinders
NOTE: The maximum cylinder drift allowed is 1.300 inch (33 mm) in ten
minutes with no bucket or attachment, measured at the lift cylinder
rod.
Left Side
1. Lower the lift arms all the way down. Stop the engine. Activate all the
hydraulic controls to release the hydraulic pressure.
Lift the loader and put jackstands Remove Hose

under the frame so there is no from Base End
of Lift Cylinder
2. Open the rear door. B–02795R

Fig. 2–70 Checking Lift Cylinder
3. Disconnect the hose from the tubeline which goes to the base end of the lift
cylinder (Fig. 2–70 or 2–71). Install the plug in the tubeline.
4. Start the engine. Push the top of the lift pedal.
5. If there is fluid leakage from the hose, remove the cylinder or cylinder(s) and Right

make repairs as needed (See Paragraph 2–5.3). Side
6. Connect the hose(s) and tighten them.
8. Remove the jackstands from under the loader frame.

Remove
Hose from
Base End of
Lift Cylinder
2–5.2 Removing the Lift Cylinder
1. Install the lift arm support device in the lift cylinder that is NOT GOING TO
BE REMOVED. You can remove only one lift cylinder at a time using this B–02794
method. Fig. 2–71 Checking Lift Cylinder
(a) Two persons are needed to install the lift arm support device. One person
must be in the operator seat with the seat belt fastened until the lift arm
support device is installed.
(b) Start the engine and raise the lift arms all the way up.
(c) Have the second person install the lift arm support device over the rod
of one cylinder (Fig. 2–72).
NOTE: Make sure the lift arm support device is tight against the cylinder
rod.
(d) Lower the lift arms until the support device is held between the lift arms
and the lift cylinder.
(e) Stop the engine.
2. Activate the hydraulic controls to release the hydraulic pressure.
3. Raise the operator cab. (See Paragraph 5–1.1, Page 5–1).

6558015
Revised Oct. 94 Fig. 2–72 Lift Arm Support Device
540, 543 Loader

5. Disconnect the hoses at the
base end of the cylinder (Fig.
2–73).
6. Remove the locknut and the

bolt at the rod end of the
cylinder (Fig. 2–74).
7. Remove the pivot pin. (Fig.

2–75). Make sure to support the
lift cylinder when removing the
pivot pin.
8. Remove the locknut and the B–04391 B–04981

bolt at the base end of the
cylinder (Fig. 2–76). Fig. 2–73 Disconnect The Hoses Fig. 2–74 Removing Lockbolt
9. Remove the pivot pin (Fig.

2–77).
10. Remove the lift cylinder from

the loader.

Hydraulic Cylinder
B–04968 B–05043
Fig. 2–75 Removing Pivot Pin Fig. 2–76 Removing Lockbolt
NOTE: This procedure can be
used for both the lift and
tilt cylinders. The tools
listed will be used for
either the tilt or the lift
cylinder.

MEL1075 – Gland Nut Wrench
MEL1076 – Cylinder Wrench
NOTE: The photos in the figures B–05044 B–05025

may not be exactly the Fig. 2–77 Removing Pivot Pin Fig. 2–78 Removing End Cap
same as the cylinder you
are working on.
1. Put the base end of the cylinder

in a drain pan and move the rod
in and out to remove the fluid
from the cylinder.
2. Put the base end of the cylinder
in the vise.

cylinder with the special tool
(Fig. 2–78).
4. Remove the rod with the end

cap and piston from the cylinder B–03665 B–03670
(Fig. 2–79). Fig. 2–79 Removing Piston And Seal Fig. 2–80 Removing The Nut
540, 543 Loader

5. Remove the cylinder housing
from the vise.
6. Put the rod end in the vise and

remove the nut (Fig. 2–80).
7. Remove the piston from the rod

(Fig. 2–81).
8. Remove the O–ring (Fig. 2–82)

if so equipped.
B–03683 B–03693
Fig. 2–81 Removing The Piston Fig. 2–82 Removing The O–ring

rod (Fig. 2–83).
10. Remove the O–ring and

back–up washer from the end
cap (Fig. 2–84).

B–03685 B–04678
Fig. 2–83 Removing The End Cap Fig. 2–84 Removing The O–ring
11. Remove the wiper seal from the

12. Remove the oil seal (Fig. 2–86).
13. Remove the Teflon seal from

the piston (Fig. 2–87).
14. Remove the O–ring on the

piston (Fig. 2–88). B–04672 B–04671
15. Wash all the parts in solvent. Fig. 2–85 Removing Wiper Seal Fig. 2–86 Removing Oil Seal
Dry with air only. Destroy old
seals and O–rings.
2–5.4 Assembly Of The Hydraulic

Cylinder
MEL1032 – Rod Seal Tool
MEL1008 – Seal Installation Tool
(2.0 inch)
MEL1009 – Seal Installation Tool
(3.0 inch)
MEL10579 – Cylinder Hone
(2.0 inch)
MEL10064 – Cylinder Hone B–03689 B–03703
(3.0 inch) Fig. 2–87 Removing The Teflon Seal Fig. 2–88 Removing The O–ring
540, 543 Loader

1. Make an inspection of the parts
for scratches, nicks, bent, etc.
Replace the parts as needed.
2. Install the piston over the tool

(Fig. 2–89).
3. Install the O–ring on the piston

using the tool (Fig. 2–90).
B–03674 B–03675
Fig. 2–89 Installing The PIston Tool Fig. 2–90 Installing The O–ring
4. Install the Teflon seal over the

tool and on the piston (Fig.
2–91).
NOTE: To prevent damage to the

Teflon seal, do not turn it
into the piston groove.

5. Install the piston into the
tapered end of the tool (Fig.
2–92) to get the Teflon seal to
the piston size diameter. Leave
the piston in the tool for five B–03677 B–03673
minutes so that the Teflon seal Fig. 2–91 Installing The Teflon Seal Fig. 2–92 Installing Piston In Tool
will become the correct size.
6. Install the wiper seal with the lip

toward the outside of the end
cap (Fig. 2–93).
NOTE: The O–ring side of the oil

seal goes toward the
inside of the cylinder.
7. Install the oil seal on the rod

seal tool (Fig. 2–94). B–03682 B–03702
Fig. 2–93 Installing Oil Seal Fig. 2–94 Installing Oil Seal On Tool
8. Install the oil seal in the end cap

(Fig. 2–95).
9. Install the backup washer (Fig.

2–96).
B–03671 B–03679
Fig. 2–95 Installing Wiper Seal Fig. 2–96 Installing Back–up Washer
540, 543 Loader

10. Install the O–ring (Fig. 2–97).
11. Put oil on the wiper seal and

install the cap on the shaft (Fig.
2–98).
B–03681 B–03685
Fig. 2–97 Installing The O–ring Fig. 2–98 Installing The End Cap
12. Install the O–ring on the shaft

(Fig. 2–99) (If so equipped).
13. Remove the piston from the tool

and install the piston on the
shaft (Fig. 2–100).

14. Install the nut and tighten to the
B–03693 B–03692
following torque (Fig. 2–101):
Fig. 2–99 Installing The O–ring Fig. 2–100 Installing The Piston
Lift Cylinder 150–160 ft.–lbs.

(203–217 Nm)
Tilt Cylinder 330–360 ft.–lbs.
(447–488 Nm)
15. Inspect the cylinder bore for

scratches. Use a hone to clean
up the cylinder hone.
16. Put oil on the seals, O–rings

and end cap threads (Fig.
2–102).
B–03670 B–03691
Fig. 2–101 Tighten The Nut Fig. 2–102 Putting Oil On The Seals
17. Install the assembly in the
cylinder housing (Fig. 2–103).
18. Tighten the end cap with the

special tool (Fig. 2–104).
19. Push the cylinder rod in and out

the full length of the cylinder
housing. It must travel freely
through the full stroke of the
cylinder with no binding.
2–5.5 Installation Of The Lift

Cylinder
1. Install the lift cylinder in the B–03665 B–05025

loader. Fig. 2–103 Installing The Assembly Fig. 2–104 Tighten End Cap
540, 543 Loader

2. Install the pin in the base end of
the lift cylinder (Fig. 2–105).
3. Lift the rod end of the cylinder

up into the lift arms and install
the pin.
4. Install the bolt and locknut in the

rod end pin (Fig. 2–106).
5. Install the bolt and locknut in the

pin at the base end of the
B–04981
6. Connect the hydraulic hoses Fig. 2–106 Installing Lockbolt
(Fig. 2–108).
B–04397
Fig. 2–105 Installing Pivot Pin
8. Start the engine. Have a second person remove the lift arm stop.

9. Operate the lift arms, stop the engine and check for leaks.
10. Check the hydraulic/ hydrostatic reservoir. Add fluid as needed.
B–05043
Fig. 2–107 Installing Lockbolt
2–6 TILT CYLINDER

2–6.1 Checking The Tilt Cylinder
1. Remove the bucket, roll the Bob–Tach fully backward and stop the engine.
Activate the hydraulic controls to release the hydraulic pressure.

jackstands under the frame so
there is no danger of the
loader falling and causing
personal injury.
Remove Hose from Base

End of the Tilt Cylinder
2. Disconnect the hose that goes
to the base end of the tilt
cylinder (Fig. 2–109). B–04391 B–02790
Fig. 2–108 Tighten The Hoses Fig. 2–109 Checking Tilt Cylinder
540, 543 Loader

3. Start the engine. Push the bottom (heel) of the tilt pedal.
4. If there is leakage from the hose, remove the tilt cylinder for repair (See
Paragraph 2–6.2).
5. If there is no leakage, connect the hoses and tighten.
B–05104
Fig. 2–110 Bolt And Locknut
2–6.2 Removing The Tilt Cylinder
1. Stop the engine.
2. Activate the hydraulic controls

to release the hydraulic
pressure.
3. Remove the locknut and bolt

from the pin at the rod end of the
cylinder. (Fig. 2–110).
4. Remove the pin at the rod end

of the cylinder (Fig. 2–111). B–05105
Fig. 2–111 Removing Pivot Pin
5. Disconnect the hoses from the

tilt cylinder (Fig. 2–112).

from the base end of the tilt
B–02790 B–04892
Fig. 2–112 Hydraulic Hoses Fig. 2–113 Bolt And Locknut
7. Remove the pin at the base end

of the cylinder (Fig. 2–114).
8. Remove the tilt cylinder from

the lift arms.
NOTE: When repairing the tilt

cylinder, use the same
procedure as when
repairing the lift cylinders
(See Paragraph 2–5.3).
Always use new O–rings
when repairing the tilt B–04891
cylinder. Fig. 2–114 Removing The Base End Pin
540, 543 Loader

2–6.3 Installation Of The Tilt
Cylinder
1. Install the tilt cylinder in the lift

arms.
2. Install the base end pin into the

tilt cylinder to hold in position.
3. Install the bolt and locknut and

Nm) torque (Fig. 2–113).
B–05113
4. Connect the hydraulic hoses to
the tilt cylinder and tighten (Fig. Fig. 2–115 Installing The Rod End Pin
2–112).
5. Install the rod end of the tilt cylinder in the Bob–Tach frame.
6. Install the pin in the rod end of the tilt cylinder (Fig. 2–115).
7. Install the bolt and locknut and tighten to 16–20 ft.–lbs. (22–27 Nm) torque
(Fig. 2–110).
8. Add grease to the grease fitting.

9. Start the engine and operate the tilt cylinder. Stop the engine and check for
leaks.
10. Check the hydraulic/hydrostatic reservoir. Add fluid as needed (See Section
8 for the correct fluid).
2–7 HYDRAULIC/HYDROSTATIC RESERVOIR

2–7.1 Removing The Hydraulic/Hydrostatic Reservoir B–04916
Fig. 2–116 Harness Bracket
1. Raise the operator cab (See
2. Remove the harness bracket
(Fig. 2–116).
3. Remove the fluid from the

reservoir (See Paragraph
1–6.3, Page 1–14).
4. Disconnect the hose at the

bottom of the reservoir (Fig.
2–117).
5. Remove the bolt holding the

strap in position (Fig. 2–118).
6. Remove the hydraulic/

hydrostatic reservoir.
B–04920 B–05948
Fig. 2–117 Reservoir Hoses Fig. 2–118 Reservoir Bracket
540, 543 Loader

2–7.2 Installation Of The
Hydraulic/Hydrostatic Reservoir
1. Install the reservoir into the

correct location.
2. Install the strap and tighten the
bolt (Fig. 2–118).
3. Install the hose at the bottom of

the reservoir (Fig. 2–117).
4. Install the harness bracket (Fig.

2–116). B–05729 B–05164
Fig. 2–119 Hose Clamp Fig. 2–120 Hose Fitting
5. Fill the reservoir with the correct
fluid (See Paragraph 1–6.2,
Page 1–13).

Paragraph 5–1.2, Page 5–1a).
7. Start the engine and operate

the hydraulic controls. Stop the
engine and check for leaks.

as needed.
B–05262 B–05261
Fig. 2–121 Hose Fitting Fig. 2–122 Air Shrouding Nut
2–8 OIL COOLER

2–8.1 Removing The Oil Cooler
(540)
1. Remove the hose clamp from

the rear of the loader frame
(Fig. 2–119).
2. Disconnect the hoses from the

elbow fittings at the oil cooler
(Fig. 2–120 & 2–121). Install
plugs in the hoses.
3. Remove the elbow fittings from

the oil cooler and install plugs.
4. Remove the nuts that hold the

air shrouding to the rear door
(Fig. 2–122).
5. Remove the air shrouding from B–05304

the rear door (Fig. 2–123). Fig. 2–123 Oil Cooler Air Shrouding
6. Remove the oil cooler from the
rear door (Fig. 2–124).
2–8.2 Installation Of The Oil

Cooler (540)
1. Install the oil cooler in the rear

door (Fig. 2–124). Make sure
the rubber mounting is pushed
on the oil cooler.
2. Install the air shrouding over the

oil cooler (Fig. 2–122).
3. Install the nuts on the air

shrouding and tighten (Fig.
2–121).
4. Remove the plugs from the oil B–05303

cooler and install the elbow Fig. 2–124 Oil Cooler Assembly (540)
fittings.
5. Remove the plugs from the

hoses, install the hoses on the
fittings and tighten.

6. Install the hose clamp and
tighten.
7. Start the engine and operate

the loader. Stop the engine and
check for leaks.

as needed.
2–8.3 Removing The Oil Cooler

(543)
1. Remove the radiator assembly B–05949

from the loader (See Paragraph Fig. 2–125 Oil Cooler Assembly (543)
7B–3.4, Page 7B–12).
2. Remove the oil cooler from the radiator mounting bracket (Fig. 2–125).
2–8.4 Installation Of The Oil Cooler (543)
1. Install the oil cooler on the radiator mounting bracket and tighten the bolts
(Fig. 2–125).
2. Install the radiator and oil cooler assembly into the loader (See Paragraph
7B–3.4, Page 7B–12).
2–9 10 MICRON FILTER BY–PASS VALVE

2–9.1 Remove The By–Pass Valve
1. Remove the hydraulic filter.
2. Remove the hoses and the tubelines from the filter head.
B–04904
3. Remove the filter head (Fig. 2–126) from the loader. Fig. 2–126 Filter Head
540, 543 Loader

4. Put the filter head in a vise.
5. Remove the plug (Fig. 2–127)

from the filter head.
6. Remove the spring and poppet

(Fig. 2–128).
7. Check the poppet and the

seating area for damage.
Check the O–ring on the plug
for damage.
2–9.2 Installation of the By–Pass B–04903
Valve Fig. 2–127 By–Pass Valve Plug
1. Install the by–pass valve into
the filter head (Fig. 2–128).
2. Install the filter head into the B–04906

loader (Fig. 2–126). Fig. 2–128 By–Pass Valve
3. Connect the hose and the
tubeline and tighten.
4. Install a new filter element.

2–10 CONTROL PEDAL, LINKAGE
AND LOCKS
2–10.1 Removing The Control
Pedal
1. Stop the engine and lower the

lift arms.
DO NOT work on the loader B–04473 B–04469

with the lift arms in a raised Fig. 2–129 Pedal Linkage Fig. 2–130 Linkage Hair Pin
position without support by
lift arm stop.
2. Disconnect the linkage from the

pedal (Fig. 2–129).
3. Remove the hair pin from the Bolt (3/8 x 1 1/2”)

pivot pins (Fig. 2–130).
Washer
4. Remove the pedal from the Bushing B–04475
pivot bracket.
Pedal
5. Remove the bushing from the
pedal.
2–10.2 Installation Of The Control

Pedal Rubber
Bushing
1. Using a vise, install the new Linkage
bushings in the pedal (Fig. B–04383
2–131). Fig. 2–131 Install Pedal Bushing
540, 543 Loader

2. Start the pivot pins into the
pedal (Fig. 2–132).
3. Put the pedal into the pivot

bracket and push the pivot pins
into position.
4. Install the hair pins.
5. Connect the linkage to the

pedal.
2–10.3 Adjusting the Control

Pedal
Loosen the nuts (Fig. 2–133) and
slide the pivot bracket backward or
forward until there is 1.500 inch (38
mm) under the rear edge of the pedal B–04466 B–04478
(Fig. 2–134). Tighten the nuts to
25–28 ft.–lbs. (34–38 Nm) torque. Fig. 2–132 Installing Pivot Pins Fig. 2–133 Adjusting Pedals

1.500” (38 mm)
A–02756
Fig. 2–134 Control Pedal Adjustment
2–10.4 Pedal Lock Linkage

If you remove the pedal lock linkage,
use the following procedure for
installation:
1. Install the bolts (Fig. 2–135, 2

Item 1) from the outside of the
fender. 3
2
2. Install a plastic washer (Fig.
2–135, Item 2).
3. Install the lock (Fig. 2–135, Item 1 3

3).
4. Put LOCTITE on the threads of 1

the bolts.
D–01548
Fig. 2–135 Pedal Lock Linkage
540, 543 Loader

5. Install the special nuts and plastic washers (Fig. 2–136). Make sure the
special nut goes tight against the fender and that the plastic washers go over
the shoulder of the special nut.
6. Put LOCTITE on the threads of the bolt and tighten the special nut to 25
ft.–lbs. (34 Nm) torque.
7. Loosen the nuts on the tab (Fig. 2–137, Item 1). Put the pedal in the neutral
position and tighten the nuts to 25 ft.–lbs. (34 Nm) torque.
AVOID INJURY OR DEATH

Adjust locking tabs on pedal control
WARNING linkage so that lift and tilt control
pedals are locked in neutral when the
seat bar is up.
W–2104–1285
B–05260
Fig. 2–136 Special Nut And Washer

B–04043
Fig. 2–137 Pedal Lock
540, 543 Loader

85 of 322
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–HydraulicSystemSectionPages11–28
540, 543 Loader

HYDROSTATIC SYSTEM
Paragraph Page
Number Number
HYDROSTATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6 3–10
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7 3–19
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . 3–2 3–2

PORT BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5 3–8 HYDROSTATIC
SYSTEM
STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 3–3
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4 3–5
TOWING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . 3–8 3–32

Avoid contact with leaking hydraulic
fluid which under pressure can be
forced through the skin. Never check
for leaks in a hydraulic system with
WARNING your bare hands. Use a piece of
wood or cardboard. If your skin is
penetrated by a fluid under pressure,
consult a qualified medical service.

without instructions or taking the A–02850
WARNING After making the repair or
death.
540, 543 Loader

Revised Oct. 83
540, 543 Loader

HYDROSTATIC SYSTEM
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2, 3, 4, 5, 19

No drive on one side in both directions. 2, 3, 5, 6, 7, 8
The loader does not move in a straight line. 2, 3, 4, 6, 8, 9, 10, 19
The hydrostatic system is overheating. 4, 11, 12, 13, 14, 15
The oil light comes ON. 16, 17, 18
1. The hydrostatic system has a fluid leak.

2. The steering linkage needs adjustment.

3. The high pressure replenishing valve(s) are defective.
4. The shuttle valve in the hydrostatic motor has a defect.
5. The balance plate in the hydrostatic motor seals are defective.
6. The hydrostatic pumps have a defect.
7. The final drive chain is broken.
8. The hydrostatic motor has a defect.
9. The tires do not have the correct tire pressure.
10. The tires are not the same size.
11. The hydrostatic fluid is not at the correct level.
12. The oil cooler has a restriction (Externally or Internally).
13. The temperature sending switch is not operating correctly.
14. The control valve is not operating correctly.
15. The loader is not being operated at the correct RPM.
16. The sender has a defect.
17. There is low charge pressure.
18. The charge relief has a defect.
19. Steering lever is obstructed.
540, 543 Loader

a
3–2 HYDROSTATIC SYSTEM CHARGE FLUID
INFORMATION
When making repairs on the FUNCTION 1

hydrostatic system, keep all
parts clean and remove all the Valve Moves for
dirt from the area before you Charge Fluid Replacement
begin disassembly. Always
use caps and plugs to keep
debris out of the system.
FUNCTION 2
Valve Stays on Seat to Hold
3–2.1 High Pressure Relief High Pressure for Drive
Replenishing Valves Function
The high pressure relief replenishing
valves are used both in forward and
reverse travel (Fig. 3–1 and 3–2).

The functions of the high pressure
relief replenishing valves are as FUNCTION 3
follows: Valve Release Very High
Pressure To Protect System C–02526
1. Give replacement fluid to the Fig. 3–1 Forward Function Of The Valve
low pressure side of the closed
hydrostatic circuit.
Replacement fluid is needed
because of the normal inside
leakage and the controlled flow
to the oil cooler for cooling (Fig. CHARGE FLUID
3–1, Function 1 and Fig. 3–2,
Function 1).
2. To keep the high pressure flow
of fluid out of the low pressure
side of the closed hydrostatic
circuit (Fig. 3–1, Function 2 and
Fig. 3–2, Function 2).
3. They will also release very high

pressure caused by a high
overload when traveling in a FUNCTION 1 Valve Moves for
forward direction (Fig. 3–1, Charge Fluid Replacement
Function 3).
See Paragraph 3–7.1 to check the

valves.
FUNCTION 2
Valve Stays on Seat to Hold
High Pressure for Drive
C–02526
Fig. 3–2 Reverse Function Of The Valve
540, 543 Loader

3–3 STEERING LEVERS
3–3.1 Removing Steering Levers
1. Stop the engine.
2. Raise the operator cab. (See

3. Remove the front panel (Fig.

3–3).
4. Remove the bolts and remove

the side shields (Fig. 3–4) on
both sides.
B–05210 B–05327
Fig. 3–3 Removing Front Panel Fig. 3–4 Removing Side Shield
5. Remove the bolts from the

steering lever shields (Fig. 3–5)
on both sides. The shields can

be removed with the steering
levers.
B–05328 B–05329
Fig. 3–5 Removing Steering Lever Shield Fig. 3–6 Disconnect Auxiliary Linkage
6. Disconnect the steering linkage

at the steering levers (Fig. 3–7).
7. Remove the bolts at the pivot

bearings (Fig. 3–8) both sides
of the steering levers.
8. Remove the steering lever

assembly from the loader (Fig.
3–9).
B–06024 B–05331
Fig. 3–7 Disconnect Steering Linkage Fig. 3–8 Removing Pivot Bearings
540, 543 Loader

3–3.2 Repairing The Steering Levers
1. Remove the rubber bushings and Teflon bushings from the steering levers.
2. Install new rubber bushings into the steering levers, using two sockets and
a vise (Fig. 3–10).
3. Install new Teflon bushings on the steering levers (Fig. 3–11).
4. Install the two steering levers assemblies together (Fig. 3–12).
5. Check the pivot bearings. Replace as needed.
B–05332
Fig. 3–9 Steering Lever Assembly
3–3.3 Installing The Steering

Levers

1. Install the steering levers
assembly into the loader (Fig.
3–9).
2. Install the bolts and nuts in the

pivot bearings (both sides) and B–04450
Nm) torque (Fig. 3–8). Spacer
3. Install the steering linkage (Fig. Washer
3–7) do not tighten the nuts.
4. Connect the auxiliary linkage at Bolt

the right steering lever (Fig. Rubber
Bushing (3/8” x 1–5/8”)
3–6). Adjust the linkage so
when the steering lever is C–02662
moved, for loader travel, the Fig. 3–10 Installing Bushings
linkage does not move in or out.
5. Install the bolts in the steering

lever shields and tighten (Fig.
3–5).
6. Install the side shields (both Teflon

sides) and tighten the bolts Bushing Teflon
(Fig. 3–4). Bushing
7. Install the front panel (Fig.3–3).
8. Make adjustment of the

steering linkage (See
Paragraph 3–4.1).

B–04448
Fig. 3–11 Installing Teflon Bushings
540, 543 Loader

3–4 STEERING LINKAGE
3–4.1 Adjustment Of The Steering
Linkage

2. Loosen the nuts and bolts at the

steering levers (Fig. 3–13).
Teflon
3. Loosen the nuts and bolts at the Bushing
B–04447
pintle levers (Fig. 3–14).
Fig. 3–12 Installing The Steering Levers Together
WARNING
jackstands under the loader
frame so there is no danger of
the loader falling and causing
personal injury.

WARNING
DO NOT work on the loader
with the lift arms in a raised
position without support by a
lift arm support device.
B–06024 B–06025
Fig. 3–13 Steering Linkage Bolts Fig. 3–14 Pintle Lever Bolts
4. Start the engine and run at a slow RPM (See Paragraph 5–1.3, Page 5–2).
5. Move the left steering lever until the tires do not turn (neutral).
6. Adjust the rear pintle bar (Fig. 3–15) so that the bar is tight against both lobes
of the pintle lever and the transmission is still in the neutral position. Tighten
the bolts on the bar to 28 ft.–lbs. (38 Nm) torque.
7. Move the left steering lever forward and backward and let the transmission
return to the neutral position. If the transmission does not return to the
neutral position, make the adjustment again.
B–05334
Fig. 3–15 Pintle Bar Bolts
540, 543 Loader

93 of 322
Revised May 94 –3–5– Service Manual
8. Move the right steering lever
until the tires do not turn
(neutral).
9. Adjust the front pintle bar so

that the bar is tight against the
lobes of the pintle lever and the
transmission is still in the
neutral position (Fig. 3–16).
Tighten the bolts on the bar to
28 ft.–lbs. (38 Nm) torque.
10. Move both steering levers

forward and backward and let
them return to neutral position,
make the adjustment if the
transmission does not return to
neutral.
11. Install new locknuts on each B–05335 B–06024

bolt that holds the steering Fig. 3–16 Pintle Bar Bolts Fig. 3–17 Steering Linkage Bolts
linkage to the pintle levers and
tighten to 23 ft.–lbs. (31 Nm)
torque.
12. Install new locknuts on the bolts at the front end of the steering linkage and
tighten to 23 ft.–lbs. (31 Nm) torque.

3–4.2 Removing The Steering Linkage
1. Raise the operator cab (See Paragraph 5–1.1, Page 5–1).
2. Remove the nuts and bolts at the steering levers (Fig. 3–17).
3. Remove the nuts and bolts at the pintle levers (Fig. 3–18).
4. Remove the bolt and nut from the centering spring (Fig. 3–19).
Installation: Compress centering spring to 2.400 inch (51 mm). B–06026

Fig. 3–18 Pintle Lever Bolts
5. Remove the fluid from the

1.6–3, Page 1–14).
6. Remove the high pressure

hoses from the hydrostatic
pumps.
7. Remove the hose fittings (Front

and rear) (Fig. 3–20).
B–06027 B–06028
Fig. 3–19 Centering Spring Bolt Fig. 3–20 Hose Fittings
540, 543 Loader

Revised Oct. 94
8. Remove the bolts from the front pintle bar and remove the bar (Fig. 3–21).
9. Slide the centering bar forward and remove it from the pump (Fig. 3–22).
10. Remove the pintle levers (Fig. 3–23) and guides from the pump shafts.
3–4.3 Repairing The Pintle Lever
1. Remove the lobes from the pintle lever (Fig. 3–24).
2. Remove the rubber bushings from the pintle levers. B–06029

Fig. 3–21 Pintle Bar Bolt
3. Install the new runner bushings, using two sockets and a vise (Fig. 3–25) in
the pintle lever.
4. Install the new lobes on the pintle lever and tighten the bolts to 25–28 ft.–lbs.
(34–38 Nm) torque.
3–4.4 Installing The Steering

Linkage

NOTE: Put LOCTITE on the shaft
before assembly.
1. Install the bushing and guide in

the pintle lever.
2. Install the key on the shaft of the

hydrostatic pump.
3. Tighten the bolt on the pintle

lever to 40–50 ft.–lbs. (54–68
Nm) torque (Fig. 3–23, Item 1).
4. Install the centering bar into the

Teflon guides on the front and
rear pintle levers. B–06030
Fig. 3–22 Removing The Centering Bar
5. Install the front pintle bar (Fig.
3–21). Do not tighten the bolts.
6. Install the hose fittings (Fig.

3–20) and the high pressure
hoses.
7. Install the centering spring, bolt

and nut (Fig. 3–19).
8. Install the steering linkage at

the pintle levers and the
steering levers. Do not tighten
the nuts.
1
B–06031 B–04470
Fig. 3–23 Pintle Lever Fig. 3–24 Pintle Lever Cam
540, 543 Loader

95 of 322
10. Add fluid to the
hydraulic/hydrostatic reservoir Front Pintle Lever
(See Section 8 for the correct Washer
fluid).
11. Make the adjustment to the Rubber

steering linkage (See Bushing
Paragraph 3–4.1).
3–5 PORT BLOCK B–04386

Rear Pintle Lever
3–5.1 Removing The Port Block
Rubber
Washer Bushing B–04385 B–04471
Always use caps or plugs in Fig. 3–25 Installing Bushings
openings or ports to keep
debris out of the hydrostatic
system.
1
1. Stop the engine. Remove the

hydraulic/hydrostatic fluid from
the reservoir (See Paragraph
1–6.3, Page 1–14).

3. Remove the side shield which is

over the port block.
4. Remove the tubeline (Fig.

3–26, Item 1).
2
5. Remove reservoir hose (Fig. 4
3–26, Item 2). 3
B–06032
6. Remove the charge pressure Fig. 3–26 Port Block Assembly
hose (Fig. 3–26, Item 3).
7. Remove the case drain hoses

(Fig. 3–26, Item 4).
8. Disconnect the wire from the

temperature switch (Fig. 3–27).

port block and remove the port
block from the loader.
3–5.2 Installing The Port Block
1. Make sure the port block is clean before installation.
2. Install the port block in the loader. Install the bolts and tighten them.
3. Install the case drain hoses (Fig. 3–26, Item 4).
B–06033
Fig. 3–27 Temperature Switch Wire
540, 543 Loader

4. Install the charge pressure hose (Fig. 3–26, Item 3).
5. Connect the reservoir hose (Fig. 3–26, Item 2).
6. Install the tubeline (Fig. 3–26, Item 1).
7. Connect the wire to the temperature switch (Fig. 3–27).
8. Put the correct fluid in the hydraulic/hydrostatic reservoir (See Section 8 for
the correct fluid).
9. Lower the operator cab (See Paragraph 5–1.2, Page 5–1).

B–06034
Fig. 3–28 By–Pass Valve
3–5.3 By–Pass Valve
1. Stop the engine. Remove the hydraulic/hydrostatic fluid from the reservoir
(See Paragraph 1–6.3, Page 1–14).
2. Remove the tubeline from the port block (Fig. 3–26, Item 1).
3. Remove the fitting from the port block.
4. Remove the poppet and spring (Fig. 3–28).
5. Clean and inspect the parts. Replace as needed.

6. Install new O–ring, install the spring, poppet and fitting and tighten the fitting.
7. Install the tubeline.
B–06035
3–5.4 Charge By–Pass Valve Fig. 3–29 Temperature Switch
1. Disconnect the wire from the temperature switch (Fig. 3–27).

2. Remove the temperature switch (Fig. 3–29).
3. Remove the plug from the port block (Fig. 3–30).
4. Remove the spring and poppet (Fig. 3–31).
5. Clean and inspect the parts. Replace as needed.
6. Install a new O–ring, install the poppet, spring and the plug and tighten the
plug.
7. Install the temperature switch (Fig. 3–29).
8. Connect the wire to the temperature switch.
B–06036
9. Add the correct fluid to the hydraulic/hydrostatic reservoir (See Section 8 for Fig. 3–30 Removing The Plug
the correct type fluid).
3–6 HYDROSTATIC MOTOR
When making repairs on hydrostatic

or hydraulic system, keep loader and
parts clean. Remove dirt and debris
IMPORTANT from the work area. Use caps and
plugs to keep dirt out of the
tubelines, hoses or ports.
I–2154–1297
B–06037
Fig. 3–31 Charge By–Pass Valve
540, 543 Loader

3–6.1 Removing The Hydrostatic Motor

loader is changed by removal of lift
arms or engine, or when it is
necessary to rotate axles, jackstands
should be put under both front axles
WARNING and both rear corners of frame.
Blocks by wheels can be climbed and
do not stop loader. W–2312–0498
Never work on loader with lift arms

up unless lift arms are held by a lift
arm support device.
W–1019
Motors With Keyed–Shaft:

1. Remove the tires and wheels from the side of the loader where the motor is
going to be removed.
3. Remove the hydrostatic pumps (See Paragraph 3–7.3).
4. Remove the cover/brake assembly (See Paragraph 4–1.2, Page 4–1).
5. Only the front drive chain has to be removed so that the motor can be
removed (See Paragraph 4–2.1, Page 4–5).

6. Remove the motor cover bolts (Fig. 3–32).
7. Remove the motor cover (Fig. 3–33).
NOTE: Mark the hoses so they will be installed correctly.
B–05341
8. Disconnect the case drain hose. Fig. 3–32 Removing Cover Bolts
9. Disconnect the high pressure hoses.
10. Remove the bolts from the hydrostatic motor.
11. Position the hydrostatic motor so that the rear drive chain can be removed
from the motor sprocket. Remove the motor from the loader.
Motors With Splined–Shaft:
1. Remove the tires and wheels from the side of the loader that the motor is
going to be removed from.
3. Remove the motor cover bolts (Fig. 3–32).
4. Remove the motor cover (Fig. 3–33).
B–09985
NOTE: Mark the hoses so they can be installed correctly.
Fig. 3–33 Removing Motor Cover
5. Disconnect the case drain hose from the motor.
6. Disconnect the high pressure hoses from the motor.
7. Remove the brake cover.
8. Remove the nut at the end of the brake linkage rod and remove the brake
cover from the linkage.
9. Install the brake linkage rod and nut.
10. Put the parking brake in the locked position.
11. Remove the nuts from the motor flange.
12. Remove the hydrostatic motor from the chaincase.
NOTE: When the motor is removed from the chaincase the chain sprocket
may pull out of the brake disc and fall into the chaincase. When the
motor is installed in the chaincase the chain sprocket will have to B–05117
be aligned in the brake disc (See Paragraph 3–6.5). Fig. 3–34 Marking The Motor
540, 543 Loader

98 94
3–6.2 Disassembly of the
Hydrostatic Motor
NOTE: Clean the outside of the

motor before disassembly.
Keep all the parts of the
motor clean.
1. Put the motor in a vise, holding

it by the mounting flange with
the shaft in the down position.
Put a mark across the motor for
correct assembly (Fig. 3–34).
B–05118 B–05120
2. Remove the four bolts from the
motor (Fig. 3–35). Fig. 3–35 Removing Motor Bolts Fig. 3–36 Removing The Valve Housing
3. Lift the valve housing (Fig.

3–36) straight up. If done
carefully, the springs and
balance plate will stay on the
valve.
4. Put the valve housing on the

bench with the open end up.
5. Remove the two O–rings (small

and large) (Fig. 3–37) from the
valve housing.
NOTE: Put the machined surface B–05126 B–05127

of the motor on a soft cloth.
Fig. 3–37 Removing O–rings Fig. 3–38 Removing The Plug
6. Remove the plug from the valve

housing (Fig. 3–38).
7. Remove the spring, dash pot

and poppet (Fig. 3–39).
8. Use a punch, remove the

poppet, spring, O–ring dash pot
and the plug and the shuttle
(Fig. 3–40).
B–05128 B–05129
Fig. 3–39 Removing The Springs Fig. 3–40 Removing Shuttle Valve
9. Remove the two springs from

the balance plate (Fig. 3–41).
10. Remove the balance plate.
11. Remove the seals from the

balance plate (Fig. 3–42).
B–05124 B–05130
Fig. 3–41 Removing The Springs Fig. 3–42 Balance Plate Seals
540, 543 Loader

12. Remove the valve (Fig. 3–43).
13. Remove the valve plate (Fig.

3–44).
B–05134 B–05123
Fig. 3–43 Removing The Valve Fig. 3–44 Removing The Valve Plate
14. Remove the valve drive (Fig.

3–45).
15. Remove the geroler (Fig.

3–46). Make sure the rollers are
kept in the geroler.

16. Remove the two O–rings from
the geroler.
B–05122 B–05121
Fig. 3–45 Removing Valve Drive Fig. 3–46 Removing The Geroler
17. Remove the drive shaft (Fig.

3–47).
18. Remove the O–rings (large and

small) from the bearing housing
(Fig. 3–48).
B–05119 B–05125
Fig. 3–47 Removing The Drive Shaft Fig. 3–48 Removing The O–rings
19. Turn the bearing housing over

in the vise and remove the eight
bolts (Fig. 3–49).
20. Using a plastic hammer, tap the

mounting flange from the
B–05132 B–05133
Fig. 3–49 Removing The Bolts Fig. 3–50 Removing The Housing
540, 543 Loader

NOTE: To remove the seal and
back–up washer for the
Models 109–1052–005 &
Below see figures 3–51 &
3–52. To remove the dust
seal and inner seal for the
Models 109–1052–006 &
Above see figures 3–52a &
3–52b.
21. Remove the back–up washer

and seal from the mounting
flange (Fig. 3–51 & 3–52). B–05141 B–05152
Fig. 3–51 Removing Back–up Washer Fig. 3–52 Removing Seal
22. Remove the dust seal and inner

seal from the mounting flange
(Fig. 3–52a & 3–53b).

B–06769 B–06768
Fig. 3–52a Removing Dust Seal Fig. 3–52b Removing Inner Seal
23. Remove the large O–ring from Shaft Face Seal

the mounting flange (Fig. Square Key
3–53). 3–1/2” O–ring
Mounting
Flange
24. Use a press to remove the shaft
and bearing assembly (Fig. Inner Seal
3–54). Quad Ring
Bearing
Housing
25. Remove the shaft surface seal Shaft & Bearing

from the bore of the bearing Assembly
housing (Fig. 3–55). Cap Screws (8)
Back–up Washer D–01493R
Mounting
Flange
Shaft & Bearing
Dust Assembly
Seal
Inner
Seal
D–01650 D–01678
Fig. 3–53 Drive End For The Hydrostatic Motor
540, 543 Loader

Revised Oct. 94
3–6.3 Hydrostatic Motor
Inspection
Before the hydrostatic motor is
assembled, check the following items
and replace as needed.
(a) Check the geroler (Fig. 3–56).
(b) Check the geroler rollers (Fig. B–05140

3–57). Fig. 3–55 Removing Shaft Seal
(c) Check the rotor. B–06927

Fig. 3–54 Removing The Shaft Assembly
(d) Check the valve plate (Fig. 3–58).

(e) Check the valve (Fig. 3–59 &
3–60).
B–04643
Fig. 3–56 Checking Geroler
(f) Check the balance plate (Fig.

3–61).
(g) Check the valve drive shaft and

the main drive shaft for wear.
(h) Check the end plate for

scratches.
B–04631 B–04634
Fig. 3–57 Checking Rollers Fig. 3–58 Checking Valve Plate
(i) Check the shuttle valve assembly

(Fig. 3–62).
Check all the contact surfaces.

Replace any parts that have scratches
or are worn that can cause leakage.
Clean all the parts in solvent and use
air pressure to dry the parts. DO NOT
use cloth or paper because small
pieces of material can get into the
hydrostatic system and cause
damage. DO NOT use sandpaper or
a file to remove scratches on any of
the parts. B–04638 B–04626
Fig. 3–59 Checking Valve Fig. 3–60 Checking Valve
540, 543 Loader

Revised Dec. 83
3–6.4 Assembly Of The
Hydrostatic Motor (Fig. 3–63)
The tool listed will be needed to do

MEL1015 – Seal Tool
(Model 109–1052–006 & Above)
B–04625
Fig. 3–61 Checking Balance Plate
Use a top grease or Vaseline

petroleum jelly to lubricate the
seals and O–rings.
NOTE: Always use a NEW seal kit

when assembling the
hydrostatic motor.

A–02774
Fig. 3–62 Shuttle Valve Assembly
Model 109–1062–005 & Below
Back–up
Washer
4
3 5
D–01439R
Model 109–1052–006 Thru 109–1173–006
Model 109–1173–006 &

Dust Seal Above
Inner 1
Seal
2
5
D–01650 D–01650 D–01678
Fig. 3–63 Hydrostatic Motor Assembly
540, 543 Loader

103 of Dec.
Revised 322 83 –3–15– Service Manual
1. Put the bearing housing on the
smooth surface with the largest
opening up.
2. Take the largest diameter half

of the seal tool and lubricate the
inside.
3. Install the seal tool into the

bearing housing (Fig. 3–64).
4. Install the shaft face seal (with

the inside edge up) into the seal
tool. B–05138 B–05137
Fig. 3–64 Installing Seal Tool Fig. 3–65 Installing The Seal
5. Install the small diameter half of
the seal tool and push the seal
into the correct position (Fig.
3–65).
6. Press the shaft and bearing assembly into the housing (Fig. 3–66). Be
careful not to damage the shaft seal. Turn the shaft several times to make
sure that the shaft is free.

NOTE: If the shaft and bearing assembly is damaged it must be replaced
as a complete unit. There are no replacement parts in the shaft
bearing assembly.
7. Lubricate the 3.500 inch (88,9 mm) diameter O–ring (Fig. 3–63, Item 1). B–06928
Install the O–ring in the bearing housing (Item 2). Fig. 3–66 Installing Shaft Assembly
8. Model 109–1052–005 &

Below Only: Install the
back–up washer (Fig. 3–63,
Item 3) and the seal (Item 4)
into the mounting flange. The
seal must be toward the inside
of the motor. Lubricate the
inside of the seal.
Model 109–1052–006 &
Above Only: Install the inner
seal, using the tool, into the
mounting flange (Fig. 3–66a).
Install the dust seal, using the
tool, into the outside of the
mounting flange (Fig. 3–66b).
B–06770 B–06771
Fig. 3–66a Installing Inner Seal Fig. 3–66b Installing Dust Seal
540, 543 Loader

Revised Dec. 83
9. Turn the mounting flange while installing it over the shaft. Be careful not to
damage the seals.
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–HydrostaticSystemSectionPages1–17
2 4
7 6
10. Put oil on the threads of the eight bolts (Fig. 3–67). Install the bolts in the
mounting flange and tighten them with your hand only.
11. Put the motor in a vise and tighten the bolts evenly to 250 in.–lbs. (28 Nm)
torque. Use the correct tightening sequence (Fig. 3–67).
5 8
12. Install the key in the keyway of the shaft. 3 1
B–03042R
Fig. 3–67 Tightening Sequence
13. Put the motor in a vise with the output shaft down (Clamp the sides of the
mounting flange only).
14. Put a small amount of oil on the output shaft.
15. Put petroleum jelly on the 3.500 inch (88,9 mm) diameter O–ring and install
it in the outer groove in the bearing housing.
16. Install the main drive in the output shaft with the longer splined end going in

first (Fig. 3–68).
17. Put petroleum jelly on the two 0.250 inch (6,35 mm) diameter O–rings. Install
the O–rings, one on each side of the geroler ring. B–05119
Fig. 3–68 Installing Drive Shaft
540, 543 Loader

105 of Aug.
The timing of the motor controls the Rotate Valve Clockwise 1/2
direction of rotation of the drive shaft Tooth to Engage Spline
of the motor. The timing parts of the
motor are as follows (Fig. 3–69): Any One of Six Ports
Open to Outside of Valve
(a) Geroler (Item 1)
(b) Valve Drive (Item 2)
(c) Valve Plate (Item 3) 4

Largest Opening
(d) Valve (Item 4) Valve
18. Find the largest opening Case Drain

between the geroler star and Hole (2)
the geroler ring and mark the
outside of the geroler ring at Valve
that location (Fig. 3–69). Plate
2 3
19. Align the case drain hole and Valve
the three pressure holes in the Drive
geroler ring with the same holes
in the mounting flange and 1

install the geroler assembly.
Make sure to keep the rollers in Pressure
position. Geroler
Relief Hole (3) Star
Geroler
20. Install the valve drive in the Ring C–02384
geroler (Fig. 3–69, Item 2).
Fig. 3–69 Timing The Motor
NOTE: When looking through the seven holes (Fig. 3–69, Item 5) in the
valve plate, if you see a roller in all the holes, it is assembled Clockwise
incorrectly, the motor will lock–up. Rotation
21. Put petroleum jelly on the 3.500 inch (88,9 mm) diameter O–ring. Install the
O–ring on the valve plate.
22. Align the case drain hole in the valve plate with the case drain hole in the
geroler. Install the valve plate with the O–ring toward the geroler.
NOTE: Make sure the slot opening of the valve plate is in alignment with the
largest opening of the geroler.
Pressure In
23. Align the valve on the valve drive so that any one of the side openings is in
alignment with the mark you made on the outside of the geroler. Turn the
valve clockwise 1/2 tooth to engage the drive. This will give the rotation
shown when pressurized (Fig. 3–70). Pressure In
Counterclockwise
Rotation
E–01442
Fig. 3–70 Rotation Of Motor
540, 543 Loader

Revised Oct. 94
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–HydrostaticSystemSectionPages17a–17b
540, 543 Loader

24. Install the poppet, spring,
dampener, O–ring and plug in
the valve housing.
25. Install the shuttle (Fig. 3–71),

poppet, dampener and spring in
the other end of the housing.
26. Install a new O–ring on the plug

and install the plug and tighten.
27. Put petroleum jelly on the 0.250

inch (6,36 mm) O–rings and
install them on the housing (Fig. B–04645 B–05126
3–72). Fig. 3–71 Installing Shuttle Valve Fig. 3–72 Installing O–rings
28. Install the spring (Fig. 3–73) in the valve housing.

B–04644
Fig. 3–73 Installing Springs
29. Put grease on the inner and

outer seals (Fig. 3–74) and
install the seals onto the
balance plate. Make sure they Outer Balance Plate
are in the position shown in Seal Outer
figure 3–74. Seal
30. Install the pins in the balance

plate. Install the balance plate
assembly on the springs (Fig.
3–75).
31. Make sure the case drain holes

are in alignment. Install the Pin Inner Seal Pin B–03046
valve housing by putting your
finger through the port in the Fig. 3–74 Balance Plate Assembly
housing to hold the balance
plate assembly in position (Fig.
3–76).
32. Check all the surfaces that

contact each other to make
sure all the O–rings are in
position.
33. Install the bolts. Use the

sequence as shown in figure
3–77 and tighten the bolts to 50
ft.–lbs. (68 Nm) torque (Fig.
3–78).
B–04630 B–04649
Fig. 3–75 Installing Balance Plate Fig. 3–76 Installing Housing
540, 543 Loader

3–6.5 Installing The Hydrostatic Motor
Keyed–Shaft Motors:
1. Install the hydrostatic motor so that the rear drive chain can be installed on 1 3
the motor sprocket.
2. Install the four bolts into the motor housing and tighten the nuts to 105–115
ft.–lbs. (142–156 mm) torque.
3. Connect the high pressure hoses in the correct sequence (Fig. 3–79). 4 2
4. Connect the case drain hose.
5. Install the motor cover (Fig. 3–80) and tighten the bolts. A–02658
Fig. 3–77 Tighten Sequence
6. Install the front drive chain (See Paragraph 4–2.2, Page 4–6).
7. Tighten the nut at the end of the sprocket on the motor shaft to 260–300
ft.–lbs. (352–407 Nm) torque.
8. Install the cover/brake assembly (See Paragraph 4–1.4, Page 4–3).
9. Install the hydrostatic pumps (See Paragraph 3–7.7).

11. Add the correct fluid to the reservoir (See Section 8 for the correct fluid).
Splined–Shaft Motors:
1. Lift and make alignment of the chain sprocket in the brake disc. B–05118
Fig. 3–78 Tightening The Bolts
2. Using a screwdriver, hold the sprocket in the brake disc through the top of
the chaincase cover.
3. Install the O–ring on the motor mounting flange.
4. Install the motor in the chaincase and sprocket.
5. Install the nuts and tighten to 105–115 ft.–lbs. (142–156 Nm) torque.
Front
6. Release the parking brake. Of
7. Remove the nut from the brake linkage. Loader
8. Install the brake cover on the linkage rod.

9. Install the linkage rod into the brake disc linkage. Tighten the nut.
10. Install the brake cover and bolts. C–02767
Fig. 3–79 Hose Routing
11. Connect the high pressure hoses in the correct sequence (Fig. 3–79).
12. Connect the case drain hose.
13. Install the motor cover (Fig. 3–80) and tighten the bolts.
14. Install the tires and wheels.
3–6.6 Start–Up Procedure For The Hydrostatic Motor

Because of the close tolerance in the hydrostatic motor, it is important that the
motor is NOT OPERATED WITHOUT A LOAD when the motor is first used after
being repaired.
The motor must be placed under a full load condition for at least ten minutes. Full
B–09985
load can be done by pushing some heavy object or material.
Fig. 3–80 Installing Motor Cover
540, 543 Loader

109 of Oct.
3–7 HYDROSTATIC PUMP
When making repairs on hydrostatic

or hydraulic system, keep loader and
parts clean. Remove dirt and debris
IMPORTANT from the work area. Use caps and
plugs to keep dirt out of the
tubelines, hoses or ports.
I–1013
3–7.1 Checking The High Pressure Relief Replenishing Valves

If there is a loss of drive in one direction, to one side of the loader, use the following B–06038
procedure to check the high pressure relief replenishing valves: Fig. 3–81 Removing The Plug
NOTE: Check the hydrostatic pump on the side only where the drive is lost.

loader is changed by removal of the
lift arms or engine, or when it is
WARNING necessary to rotate axles,
jackstands should be put under both
front axles and both rear corners of

frame. Blocks by wheels can be
climbed and do not stop loader.
W–1034
B–06041
Never work on loader with lift arms Fig. 3–82 Removing The Plug
up unless lift arms are held by a lift
WARNING arm stop.
W–1019

2. Remove the plug for one direction (Fig. 3–81 or 3–82).
NOTE: To remove the plug (Fig. 3–82) from the right side of the pump, the
steering linkage must be removed.
3. Remove the spring and high pressure relief valve from the pump (Fig. 3–83
or 3–84). B–06042
4. Remove the plug for the other direction. Fig. 3–83 Relief Valve
5. Remove the spring and high pressure relief valve.

6. Change the valves to the opposite ports where they where removed.
7. Install the springs and plug. Start the engine and check the drive.
8. If the loss of the drive goes to the other direction of the loader, the valve which
controls that direction of the loader must be replaced.
9. If the changing of the valves does not change the direction of loss of drive.
The problem is somewhere else in the system, go to the troubleshooting
chart for other possible causes.
B–06043
Fig. 3–84 High Pressure Relief Valve
540, 543 Loader

Revised Oct. 94
3–7.2 Checking The Charge Pressure
MEL1173 Test Kit

under the loader frame so there is no
B–06081
Fig. 3–85 Removing Charge Pressure
DO NOT work on the loader with the Switch
lift arms in a raised position with out
WARNING support. Use a lift arm support
device.
2. Disconnect the wire from the pressure switch on the fitting of the charge
tubelines (Fig. 3–85).
3. Remove the pressure switch from the fitting.

4. Connect a pressure gauge (Fig. 3–86).
5. Start the engine and run it at 2500 RPM.

B–06082
6. The pressure on the gauge must read 45–65 PSI (310–448 kPa) minimum Fig. 3–86 Checking Charge Pressure
with no hydraulic action.
7. If the pressure is not correct, remove the side shield over the port block.
8. Remove the temperature switch from the port block.
9. Remove the charge pressure relief valve (See Paragraph 3–5.4).
10. Install the temperature switch and side shield.
11. Remove the gauge, install the pressure switch and connect the wire.
3–7.3 Removing The Hydrostatic Pump

540, 543 Loader

DO NOT work on the loader
with the lift arms in a raised
position without support by a
lift arm support device.
B–06044 B–06045
1. Raise the operator cab (See Fig. 3–87 Hydraulic Pump Hose Fig. 3–88 Hydraulic Pump Hose
2. Remove the front panel.
3. Remove the side shields.
4. Remove the steering linkages

5. Remove the hydraulic/

hydrostatic fluid from the

1–6.3, Page 1–14).
6. Remove the hoses from the B–06046 B–06047

hydraulic pump (Fig. 3–87 &
3–88). Fig. 3–89 Charge Tubeline Hose Fig. 3–90 Charge Tubeline Hose
7. Remove the hoses from the

charge tubeline on top of the
hydrostatic pump (Fig. 3–89 &
3–90).
8. Remove the high pressure

hoses from the hydrostatic
pump (Fig. 3–91 & 3–92) (both
sides).
B–06048 B–06049
Fig. 3–91 High Pressure Hose Fig. 3–92 High Pressure Hose
9. Remove the front pump mount

bolts (both sides) (Fig. 3–93).
Remove the washers (Fig.
3–94).
B–06050 B–06051
Fig. 3–93 Pump Mounting Bolt Fig. 3–94 Pump Mounting Washers
540, 543 Loader

Revised May 94
10. Remove the bolts (both sides)
from the rear of the hydrostatic
pump.
11. Slide the pump assembly

forward and lift up on it to
remove it from the loader (Fig.
3–95).

Hydrostatic Pump
The tool listed will be needed to do
the following procedure: B–06052
Fig. 3–95 Hydrostatic Pump Removal
MEL1219–4 – Torx Drive Bit
Keep all the hydrostatic parts

clean. Dirt in the system will
cause damage in a very short
time.

1. Remove the steering centering
mechanism from the B–06053 B–06057
hydrostatic pump (See
Paragraph 3–4.2). Fig. 3–96 Pump Coupler Fig. 3–97 Splined Gear
NOTE: The hydrostatic pump

front and rear unit are the
same and the same
procedure is used for
disassembly.
2. Remove the coupler from the

pump shaft (Fig. 3–96) (540
Loader Only).
3. Remove the bolt and the
splined gear from the pump
4. Put a mark across all the pump
sections for correct assembly. B–06058
Fig. 3–98 Removing Charge Tubeline
5. Remove the charge tubeline
between the two pumps (Fig.
3–98).
6. Remove the bolts and the
hydraulic pump (Fig. 3–99).
pump housing and the center
section (Fig. 3–100).
B–06059 B–06060
Fig. 3–99 Removing Hydraulic Pump Fig. 3–100 Pump Housing Bolts
540, 543 Loader

Revised Oct. 94
8. Separate the pump housing
from the center section.
9. Remove the coupling from the

center section (Fig. 3–101).
10. Remove the four bolts from the

center section (Fig. 3–102) and
remove the center section from
the other pump (Fig. 3–103).
B–06061 B–06062
Fig. 3–101 Center Section Coupler Fig. 3–102 Center Section Bolts
Keep all the parts for one

pump separated from the parts
for the other pump.

B–06063
Fig. 3–103 Removing Pump Center Section
11. Remove the rotating group by

putting your hand under the
rotating group and turn the
pump housing around so the
rotating group will slide into
your hand (Fig. 3–104).
Mark each piston and shoe B–06064 B–06071

assembly so they will be
returned to their original bore Fig. 3–104 Removing Rotating Group Fig. 3–105 Removing Snap Ring
in the block and plate.
12. Remove the snap ring (Fig.

3–105) from the rear housing
and hit the shaft on a block of
wood to remove the bearing
and shaft (Fig. 3–107).
13. Remove the seal and back–up

washer (Fig. 3–107).
B–06072 B–06073
Fig. 3–106 Removing The Shaft Fig. 3–107 Seal And Back–up Washer
540, 543 Loader

14. Use MEL1219–4 to remove the
cover bolts on the long pintle
15. Remove the pintle cover.
B–06065
Fig. 3–108 Pintle Cover Bolts
16. Remove the seal and the

washer (Fig. 3–109).
17. Remove the pintle shaft bearing

(Fig. 3–110).

B–06067 B–06066
Fig. 3–109 Pintle Seal And Washer Fig. 3–110 Pintle Bearing
18. Remove the cover from the

short pintle shaft (Fig. 3–111).
19. Remove the washer and O–ring

from the shaft (Fig. 3–112).
B–06068 B–06069
Fig. 3–111 Pintle Cover Fig. 3–112 Pintle O–ring And Washer
20. Remove the bearing and the

bearing race from the shaft
(Fig. 3–113).
21. Remove the camplate from the

B–06070 B–06074
Fig. 3–113 Bearing And Race Fig. 3–114 Pump Camplate
540, 543 Loader

115 of Oct.
3–7.5 Inspection Of The
Hydrostatic Pumps
Keep all the parts for one

pump separated from the parts
for the other pump.
B–06075
Fig. 3–115 Drive Shaft Inspection
1. Check the drive shafts for wear

and damage to the splines (Fig.
3–115). Check end play. It must
not exceed 0.090 inch.
2. Inspect the flat surface of the

center section, front and rear
(Fig. 3–116). The finish on the
piston block side must be

smooth and free of grooves. If
the grooves can be felt on the
finished surface with a
fingernail, replace the section.
B–06076 B–06077
Fig. 3–116 Center Section Inspection Fig. 3–117 Piston Shoe Inspection
NOTE: Make sure the piston and

shoe assembly are
returned to their original
bore on installation.
3. Inspect the rotating group for

the following items: B–06078
Fig. 3–118 Piston Block Inspection
(a) Check each piston in its
cylinder. The piston must move
freely in the bore. If the piston
does not move easily, clean the
piston and bore. Put oil on both This Dimension Must be
and try again. Maintained on All Nine Shoes Piston
Within 0.001” (0,0254 mm)
(b) Check the piston shoe for
scratches (Fig. 3–117).
(c) Check the flat surface of the Shoe
piston block for being smooth
and free of scratches (Fig. Shoe Must Swivel
3–118). Smoothly on Ball, End
Play Must Not Exceed
(d) Measure the thickness of Shoe Faces Sides 0.003” (0,076 mm)
each shoe. All the shoes must On Swash Plate
be within 0.001 inch (0,025 mm) A–01850
of each other (Fig. 3–119). Fig. 3–119 Piston/Shoe Specifications
540, 543 Loader

11692
Revised Mar. of 322 –3–26– Service Manual
(e) Inspect the shoe plate for
wear and cracks.
(f) Inspect the pins and spherical
washer for wear and damage
(Fig. 3–120). All the pins must be
the same length and must not be
bent. Check the spherical
washer for sharp edges, wear or
scratches.
NOTE: If there is any defect in the

rotating group, the B–05408 B–06079
complete unit must be
replaced. Fig. 3–120 Spherical Washer Inspection Fig. 3–121 Camplate Inspection
4. Inspect the camplate for

scratches (Fig. 3–121), the
finish must be free of grooves
and smooth. If the grooves can
be felt with the fingernail,
replace the camplate.
5. Inspect the bearings in the

pump housings (Fig. 3–122).

3–7.6 Assembling The Hydrostatic
Pumps
B–06080 B–06074
Fig. 3–122 Bearing Inspection Fig. 3–123 Installing Camplate
Use Vaseline petroleum jelly to

lubricate the seals, O–rings or
bearings.
B–06070 B–06069
Fig. 3–124 Installing Bearing And Race Fig. 3–125 Pintle O–ring And Washer
NOTE: Always use a new seal kit when assembling the hydrostatic pumps.
1. Install the camplate into the pump housing (Fig. 3–123).
2. Install the bearing race and bearing on the shaft (Fig. 3–124).
3. Install the washer and O–ring on the shaft (Fig. 3–125).
4. Install the covers on the short pintle shaft (Fig. 3–126) and tighten the
screws.
B–06068
Fig. 3–126 Installing Pintle Cover
540, 543 Loader

5. Install the pintle shaft bearing
(Fig. 3–127) on the long pintle
shaft.
6. Install the seal and washer (Fig.

3–128).
7. Install the pintle cover.
B–06066 B–06067
Fig. 3–127 Installing Bearing Fig. 3–128 Installing Seal And Washer
8. Install the cover bolts and

tighten (Fig. 3–129).
9. Install the seal and back–up

washer on the shaft (Fig.
3–130).
NOTE: Install seal in rear pump

only.

B–06065
Fig. 3–129 Installing Pintle Cover
B–06073
Fig. 3–130 Installing Seal And Washer
10. Install the drive shaft and install

the snap ring (Fig. 3–131).
11. Install the rotating group in the

B–06071 B–06064
Fig. 3–131 Installing Snap Ring Fig. 3–132 Installing Rotating Group
540, 543 Loader

11894
12. Install the center section on the
B–06063
Fig. 3–133 InstallingPump Center Section
13. Install the bolts and tighten to

17–21 ft.–lbs. (23–28 Nm)
torque (Fig. 3–134).
14. Install the coupling into the

center section (Fig. 3–135).
15. Install the other pump housing

assembly on the center section.

B–06062 B–06061
Fig. 3–134 Center Section Bolts Fig. 3–135 Center Section Coupler
16. Install the two bolts into the

pump housing and center
section and tighten to 25–28
ft.–lbs. (34–38 Nm) torque (Fig.
3–136).
17. Install the hydraulic pump on

the pump housing.
18. Install the bolts and tighten (Fig.

3–137).
B–06060 B–06059
Fig. 3–136 Pump Housing Bolts Fig. 3–137 Installing Hydraulic Pump
19. Install the charge tubeline

between the two hydrostatic
pumps (Fig. 3–138).
B–06058
Fig. 3–138 Installing Charge Tubeline
540, 543 Loader

Revised Aug. 90
20. Install the splined gear on the pump shaft.
A
21. Put LOCTITE on the thread and install the bolt.
Tighten to 25–28 ft.–lbs. (34–38 Nm) torque [A].
B–06057
22. Install the pump coupler on the splined gear [B] (540
only). B
23. Install the steering linkage on the pump assembly

B–06053
3–7.7 Installing The Hydrostatic Pumps
Install the bolts in the rear pump mount and the front
mount. Fasten the pump assembly to the rear mount C
(Using two bolts).
Put a flat metal (Example: Key Stock) against the spiders
on the drive coupler, to check coupling alignment [C].
Loosen engine mounts if necessary and move engine to
make alignment of drive coupler.
If the height alignment is not correct, add or subtract half Key Stock
thickness washers at the rear pump mount. Correct
height specifications for pump drive is shown in [D].
NOTE: Measure from engine mounting plate to B–03531

center of pump shaft. Also measure engine
distance to center of the flywheel, the two
dimensions must be as close as possible.
D
Check engagement of coupling onto spline. Maximum
clearance between pump drive flange and yoke is 0.250
inch (6,35 mm).
Add special lubricant (P/N 6599719) to the grease fittings
on the coupler.
1. Put the hydrostatic pump assembly into the loader. 9.500 ± 0.060
Make alignment of the pump coupler to the engine Engine
and slide the pump assembly into position. Mounting Plate
2. Install the bolts at the rear of the pumps to the

engine (both sides) and tighten. B–06938
540, 543 Loader

Revised Oct. 94
3. Install the washers under the front pump mounts
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–HydrostaticSystemSectionPages18–31
[A]. A
B–06051
4. Install the pump mounting bolts [B] and tighten.

B

B–06050
5. Install the high pressure hoses on the pumps (both

sides) and tighten [C] & [D]. C
B–06049
B–06048
540, 543 Loader

121 of Oct.
6. Install the hoses on the charge tubeline [A] & [B].
A
7. Install the hoses on the hydraulic pump and tighten
[C] & [D].
8. Install the steering linkage at the pintle levers and

the steering levers.
9. Install the side shields.
11. Add the correct fluid to the hydraulic/hydrostatic

reservoir (See Section 8 for the correct fluid).
B–06047
12. Before you start the engine on the loader (See
Paragraph 3–7.8 for the correct start–up
procedure).
B
13. Adjust the steering linkage (See Paragraph 3–4.1).
14. Lower the operator cab (See Paragraph 5–1.2,

Page 5–1a).
15. Remove the jackstands from under the loader

frame.

3–7.8 Start–Up Procedure For The Hydrostatic Pump
1. Make sure all the hoses and tubelines are tight.

B–06046
2. Check the hydraulic/hydrostatic reservoir, make
sure the fluid level is correct.
3. Put the steering levers in the neutral position.

C
4. Start the engine and run at a slow RPM. The charge
pump must immediately pick up fluid and fill the
system. If there is no sign of a fill in 30 seconds, stop
the engine and check for the cause.
5. After the system is full, at a slow rate move the

steering levers into the forward position. Operate
the system at a slow rate and no load until the
system is at normal operation.
6. Stop the engine. Check the reservoir. Add fluid as

needed. B–06045
7. Check all the tubelines and hoses to make sure

there are no leaks.
D
8. Go back to step 12 of installing the Hydrostatic
Pump.
NOTE: The Oil Cooler Removal And Installation is

located in the Hydraulic Section Paragraph
2–8.
B–06044
540, 543 Loader

Added Oct. 94
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–HydrostaticSystemSectionPages31a–31b
540, 543 Loader

3–8 TOWING THE BOBCAT LOADER
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–HydrostaticSystemSectionPages32
3–8.1 Installation Of The Tool For The High Pressure Relief Valves
The tool listed will be needed to do the following procedure:
MEL1220 – Relief Valve Release Tool
Moving the Bobcat loader that cannot move under it’s own power can be moved
with the following procedure:
B–06042
2. Clean the area on the right side
of the hydrostatic pumps using Fig. 3–149 High Pressure Relief Valve
solvent and compressed air.
3. Remove the top two plugs (Fig.

3–149), springs, one high
pressure relief and one
replenishing valve.
4. Install the release tool (Fig.

3–150, Item 1) into the ports
instead of the valves which
were just removed.

5. Install the plug and tighten. The
release tools will move the
opposite side valve off the seat.
6. Lower the operator cab.
7. The loader can now be safely

moved for a distance of 75–100
ft. (69–91 m) at a slow speed of
2 MPH (3,2 km/hr.).
8. After the loader is at the correct

location. Raise the operator
cab.
9. Remove the plugs and the tools

from the hydrostatic pumps.
10. Install the valves into the

correct ports from which they
were removed. B–06924
D–01607
11. Install the plugs with new Fig. 3–150 Installation Of The Towing Tool
O–rings and tighten to 55–60
ft.–lbs. (75–81 Nm) torque.
540, 543 Loader

Added Oct.124
DRIVE SYSTEM
Paragraph Page
Number Number
AXLES & BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3 4–7
CHAINCASE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4 4–10
FINAL DRIVE CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2 4–5

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 4–1
DRIVE
SYSTEM

death.
540, 543 Loader

540, 543 Loader

4–1 PARKING BRAKE
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–DriveSystemSectionPages1
Always stop the engine and engage the parking

brake before you leave the operator’s seat.
4–1.1 Parking Brake Adjustment 0.250”

(6,35 mm)
A–02414R
When the brakes are in good condition and adjusted
correctly, they will keep the loader from moving when in
the parked position.
B
1. There must be 0.250 inch (6,35 mm) of movement
under the bottom edge (heel) of the brake pedal [A]. 2
This is done by first loosening the jam nut (Item 1)
[B] and then turning the nut on the end of the linkage
rod (Item 2) [B]. The brake pucks must make
contact with the brake discs when the pedal is
moved 0.250 inch (6,35 mm), but not be fully
engaged.

1
2. The adjustment cannot be obtained by turning the
nut (Item 2) [B] or [C] the brake lever must be
removed from the cam pin.
3. The hydrostatic pumps may have to be removed or B–05181

lifted to get to the brake lever for easier removal.
4. Loosen the bolt on the brake lever. Do not remove

the bolt.
C
B–09709
5. Using pry bars and a soft hammer, hit the bolt until
the brake lever is loose from the cam pin [D].
D
6. Remove the bolt and brake lever and turn the cam
pin counterclockwise until the brake pucks make
contact with the brake discs.
7. Install the brake lever and bolt. Tighten the bolt to

65–70 ft.–lbs. (88–95 Nm) torque.
8. Install or lower the hydrostatic pumps.
9. Adjust the parking brake as outlined in step 1.
B–05188
540, 543 Loader

Revised Oct. 94
4–1.2 Parking Brake Removal
1. Raise the Operator Cab (See Paragraph 5–5.1,

A
Page 5–1).
2. Remove the front panel [A].
B–05210
540, 543 Loader

128 of
Added 322 94
Oct. –4–1a– Service Manual
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–DriveSystemSectionPages1a–1b
540, 543 Loader

3. Remove the steering levers
(See Paragraph 3–3.1, Page
3–3).
4. Remove the hydrostatic pumps

3–21).
5. Remove the brake linkage from

the pedal.
6. Remove the brake pedal (Fig.

4–5).
B–05171 B–05148
7. Remove the brake lever spring Fig. 4–5 Removing Brake Pedal Fig. 4–6 Removing Spring
(Fig. 4–6).

transmission covers (Fig. 4–7 &
4–8).

Be careful not to cause damage
to the gaskets.
B–05151 B–05149
Fig. 4–7 Removing Cover Bolts Fig. 4–8 Removing Cover Bolts
9. Using a pry bar, loosen the

transmission covers (Fig. 4–9)
and remove the covers. 2.0” 1.750”
0.375”
10. Install the brake disc tool (Fig.
4–10) on the sprocket of the
hydrostatic motor.
9.500”
B–05184 B–03027
Fig. 4–9 Removing Covers Fig. 4–10 Special Tool
540, 543 Loader

11. Loosen the bolt on the
hydrostatic motor (Fig. 4–11). Lobe Washer
Remove the disc tool.
12. Turn the retainer washer (Fig.

4–12) so that the brake disc can
be removed from the sprocket
(Fig. 4–13).
13. Remove the bolt from the brake

lever (Fig. 4–14) and remove
the brake lever.
14. Remove the brake block from B–05217

Brake Disc B–03021
the transmission cover (Fig.
4–15). Fig. 4–11 Loosening Sprocket Bolt Fig. 4–12 Retainer Washer Alignment
15. Remove the brake pucks (Fig.

4–16) from the brake block.
4–1.3 Parking Brake Inspection
1. Check the brake disc for

damage. Replace discs as
needed. DO NOT grind the
discs.

2. Check the pucks for wear or
damage. The pucks can be
turned 180° and the smooth B–05196
side used again. Fig. 4–13 Removing Disc
3. Check for a good fit between
the pucks and the bore in the
block. They must be free to
slide in the block.
B–05174
Fig. 4–14 Brake Lever Bolt
4–1.4 Parking Brake Installation
1. Install the brake pucks and

retainers into the brake block
(Fig. 4–16). Install the first and
last puck into the puck retainer.
B–05179 B–05146
Fig. 4–15 Brake Block Bolts Fig. 4–16 Removing Brake Puck
540, 543 Loader

2. Install the O–ring on the cam pin [A]. Install the cam
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–DriveSystemSectionPages2–4
pin into the brake block. Make alignment of the puck A

retainer and the cam pin.
B–05208
3. Put a bead of silicone rubber sealant on the brake

block [B]. B

B–05206
4. Install the transmission cover on the brake block

[C]. C
B–05204
5. Put LOCTITE on the bolts and tighten the bolts to

65–70 ft.–lbs. (88–95 Nm) torque [D]. D
B–05186
540, 543 Loader

13294
6. Install the brake discs on the sprocket teeth [A].
A
B–05196
7. Turn the retainer washer so the lobes will hold the

disc on the sprocket [B]. B Lobe
Washer

Brake Disc
B–03022
8. Install the disc special tool (P/N 6559556) and

tighten the sprocket bolt to 260–300 ft.–lbs.
(352–407 Nm) torque [C].
C
NOTE: Adjust the torque for correct torque (See

Table Below) when it is to be used with the
special tool.
Table For Various Lengths Of Torque Wrench

Torque Wrench Length Set Torque To
12.0 inch 150–175 ft.–lbs.
18.0 inch 180–210 ft.–lbs.
24.0 inch 200–233 ft.–lbs. C–02376
After tightening the sprocket retaining nut, check location

of the retaining washer to be sure the lobes are over the
lobes on the brake disc. If not centered, loosen the
retaining nut and adjust the washer.
540, 543 Loader

Revised Oct. 94
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–DriveSystemSectionPages4a–4b
540, 543 Loader

9. Put the transmission cover/brake assembly over
the brake discs [A]. A
10. Align the brake discs so they are centered between
the brake pucks.
11. Align the holes in the transmission cover and

gasket. Install the bolts and tighten to 16–20 ft.–lbs.
12. Install the brake lever on the cam pin. Pull the brake
lever to put the brake pucks against the discs and
install the brake lever bolt in the brake lever and
tighten 65–70 ft.–lbs. (88–95 Nm) torque.
13. Install the brake linkage, spring and brake pedal. B–05213
14. Make adjustment to the parking brake (See

Paragraph 4–1.1). B
15. Install the hydrostatic pumps (See Paragraph
3–7.7, Page 3–30).
16. Install the steering levers (See Paragraph 3–3.3,

Page 3–4).

18. Lower the operator cab (See Paragraph 5–1.2,

Page 5–1).
4–2 FINAL DRIVE CHAINS B–05210
The final drive uses the hydrostatic motors and the roller
chains. The chains do not have connector links.
C
4–2.1 Remove The Drive Chain(s)
Lift the loader and put blocks under the frame

so that there is no danger of the loader falling
and causing personal injury.

procedure:
MEL1045 – Chain Breaker
1. Raise the operator cab (See Paragraph 5–1.1, Page

5–1).
2. Remove the front panel [B].
3. Remove the steering levers (See Paragraph 3–3.1,

Page 3–3).
540, 543 Loader

135 of Oct.
4. Remove the hydrostatic pumps (See Paragraph 3–7.3, Page 3–21).
5. Remove the transmission covers and brake assembly (See Paragraph

4–1.2).
6. Remove the fluid from the chaincase (See Paragraph 4–4.1)
7. Check the drive chain for a connector link. If there is no connector link,
separate the drive chain at any link.
8. Using the chain breaker tool, separate the chain (See Page 4–5, [C]).
9. Remove the drive chain(s).

B–04663
4–2.2 Installing The Drive Chain(s) Fig. 4–25 Installing Drive Chain

MEL1037 – Chain Link Press Tool
1. Remove the axle and sprocket (See Paragraph 4–3.1) where the new drive
chain will be installed.
2. Make sure the chaincase is clean.
3. Put the drive chain into the chaincase. Put it over the sprocket of the
hydrostatic motor and pull the ends out and above the chaincase.

4. Mark the connector link plate and install the connector link into the drive
chain (Fig. 4–25).
B–04658
5. Put a flat bar under the drive chain and across the chaincase (Fig. 4–26) and
clamp to the chaincase. Fig. 4–26 Installing Bar
6. Put the plate on the connector link (Fig. 4–27) and start it into the correct
position with a pliers.
7. Install the chain link press tool (Fig. 4–28) and clamp it to the flat bar.
8. Put a torque wrench on the chain link press tool (Fig. 4–29) and tighten to
180 ft.–lbs. (244 Nm) torque to press the connector plate into position.
9. Remove the chain link press tool and the flat bar from the chain.
10. Install the axle sprocket into the chaincase and position it in line for the axle
installation.
11. Install the axle (See Paragraph 4–3.2). B–04664

Fig. 4–27 Installing Link Plate
12. Install the transmission cover/brake assembly (See Paragraph 4–1.4).
13. Install the hydrostatic pumps

3–30).
B–04659 B–04657
Fig. 4–28 Installing Chain Link Tool Fig. 4–29 Pressing Connector Link
540, 543 Loader

13694
14. Install the steering levers (See Paragraph 3–3.3, Page 3–4).
18. Add fluid to the chaincase (See Section 8 for the correct fluid).
4–3 AXLES AND BEARINGS

Removal, assembly and installation is the same for all four axles on the loader.

under the frame so that there is not

4–3.1 Removing Axle(s) and Bearings
Slide Hammer (Purchased Locally)
MEL1202A Axle Race Service Set
MEL10540
1. Remove the tire and wheel assembly.
3. Remove the front panel.
4. Remove the steering levers (See Paragraph 3–3.1, Page 3–3).
5. Remove the hydrostatic pumps (See Paragraph 3–7.3, Page 3–21).

B–03992
6. Remove the transmission cover/brake assembly (See Paragraph 4–1.2). Fig. 4–30 Sprocket Bolt
7. You may have to remove the

final drive chain to remove the
axle (See Paragraph 4–2.1).
8. Remove the bolt and washer

from the end of the axle (Fig.
4–30).
9. Use a slide hammer to remove

the axle from the inner bearing
and the sprocket (Fig. 4–31).
B–03980
Fig. 4–31 Removing The Axle
540, 543 Loader

Revised May 94
10. Move the sprocket away from the axle tube.
A
11. Pass the correct step plate from the service set,
through the outer race. Insert the long driver handle
into the step plate and drive the inner race out
toward the inside of the transmission case [A].
B–02840
12. The outer race is removed with the same step plate
and a heavy slide hammer [B].
B

13. Use a puller [C] to remove the outer bearing from
the axle. C
14. Clean and check all the parts for wear or damage.
Replace the parts as needed.
Bearing
B–02813
4–3.2 Assembly Of The Axle

D
1. Lubricate the axle seal (Item 1) [D] and install the 3
seal on the axle, with the open side of the seal 2
toward the chaincase.
1
C–02659
540, 543 Loader

13894
2. Using an arbor install the outer
bearing on the axle (Fig. 4–36).
Press only on the inner race of
the bearing (Fig. 4–37). This will Bearing
also position the seal in its
location. Oil Seal
4–3.3 Axle And Bearing Installation

MEL1051 Axle Seal Tool
MEL1202A Axle Bearing Race Set B–03981 B–03984
Fig. 4–36 Installing Outer Bearing Fig. 4–37 Installing Outer Bearing
1. Position the new inner race
over the machined disc and
install with the long threaded
rod (Fig. 4–38).
2. Position the centering disc over

the outer end of the axle tube
and tighten the nut (4–38a).
3. Put the sprocket into the

chaincase.

NOTE: The wide part of the
sprocket hub goes toward
the inside for the front
axles and toward the B–03982 B–02770
outside for the rear axles. Fig. 4–38 Installing Inner Bearing Race Fig. 4–39 Installing Inner Halves Of Tool
Pack wheel bearing cones with wheel

bearing lubricant.
4. Pack each bearing core with

wheel bearing lubricant.
5. Install the axle assembly into

the axle housing tube.
6. Install the inner halves of the

installation tool behind the outer
axle seal (Fig. 4–39).
7. Install the outer halves of the

B–02774
installation tool on the inner
halves of the tool (Fig. 4–40). Fig. 4–38a Installing Centering Disc Fig. 4–40 Installing Outer Halves Of Tool
8. Install the spring on the installation tool (Fig. 4–41).
9. Push inward and install the inner bearing.
10. Put the sprocket on the end of the axle.
11. Put the installation tool in contact with the axle housing tube. Install the
washer and bolt (Fig. 4–35, Items 2 & 3) and pull the axle to the inside to
prevent damage to the bearing and seal.
12. Using a large hammer, hit the axle hub until the axle is installed.
Spring
13. Remove the spring from the installation tool.
B–02772
Fig. 4–41 Installing Spring
540, 543 Loader

139 of Oct.
14. Remove the outer halves of the
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–DriveSystemSectionPages5–10
installation tool from the inner

halves.
15. Remove the inner halves of the

installation tool from the axle.
16. Make sure the sprocket is

installed correctly on the axle.
Put LOCTITE on the bolt and
tighten the bolt on the end of the
axle to 300–330 ft.–lbs.
(407–448 Nm) torque. Check
the axle end play. It must be
between 0.002–0.100 inch
(0,05–0,25 mm). If not, replace
the washer (Fig. 4–35, Item 3)
to get the correct end play.
17. Install the final drive chain (See B–05202

Paragraph 4–2.2). Fig. 4–42 Removing Chaincase Fluid
18. Install the transmission cover/brake assembly (See Paragraph 4–1.4).
19. Install the steering levers (See Paragraph 3–3.3, Page 3–4).

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

4–4.1 Replacing Chaincase Fluid
1. Raise the operator guard (See Paragraph 5–1.1, Page 5–1).
2. Remove the brake linkage and brake pedal (See Paragraph 4–1.2).
3. Remove the front transmission cover.
4. Use a pump (Fig. 4–42) to remove the fluid from the chaincase.
5. Use clean rags to remove any fluid that the pump did not remove and to clean
the chaincase (Fig. 4–43). B–03988
Fig. 4–43 Cleaning Chaincase
6. Use only recommended replacement fluid (See Section 8 for the correct
fluid) to fill the chaincase with 16 qts. (15 L) of fluid.
7. Install the front transmission cover.
8. Install the brake pedal and linkage (See Paragraph 4–1.4).
9. Lower the operator guard (See Paragraph 5–1.2, Page 5–1).
540, 543 Loader

Revised Oct. 94
MAIN FRAME
Paragraph Page
Number Number
BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3 5–5
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5 5–10
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2 5–3

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 5–1
PEDAL LOCK LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8 5–13

REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4 5–9
SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6 5–11
SEAT BAR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7 5–12
MAIN
FRAME

death.
540, 543 Loader

Revised Aug. 85
540, 543 Loader

MAIN FRAME
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–MainFrameSectionPages1
A
5–1 OPERATOR CAB
5–1.1 Raising The Operator Cab
1. Stop the loader on a level surface.
2. Put the lift arms all the way down or hold the lift arms
up with a LIFT ARM SUPPORT DEVICE. The LIFT
ARM SUPPORT DEVICE must be installed by a
second person while the operator is in the operator’s
seat.
3. Stop the engine, engage the brake. Disconnect the

wire harness behind the seat [A]. B–04696
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.
W–2014–0895
4. Put jackstands or blocks under the rear corners of

the Bobcat loader to keep the loader from tipping C–02599
backwards.
5. Remove the two bolt assemblies (including C CORRECT

washers) at the front corners of the operator cab
[B].
6. Earlier Models: Two persons are needed to lift the

operator cab. Avoid slippery surfaces when lifting
the operator cab.
7. Stand on the ground, one person on each side and

lift the operator cab using the grab handles and the
bottom of the operator cab [C].
8. Lift slowly until the operator cab is all the way up.
The operator cab will lock in this position (See
Paragraph 5–1.3 and install the jumper start switch B–03846
as needed).
540, 543 Loader

Revised Oct. 94
20001 & Above: Loosen the nut (both sides) at the corner
of the operator cab [A]. A Nut
Washer
Plate
Bolt Bushing
Washer
P–00150 MC–01181
Remove the nut and plate (both sides) [B].

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

P–00151 P–00152
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].
C
5–1.2 Lowering The Operator Cab
1. Stop the engine and remove the jumper start switch.
2. Two persons are needed to lower the operator cab.

Avoid slippery surfaces when lowering the operator
cab.
3. Stand on the ground, one person on each side and

pull down on the operator cab until it contacts the
lock mechanism. P–01717
If the lift arms are raised, reach for the ring on

the cable from under the lift cylinder. DO NOT
reach between the lift arms and the lift cylinder.
540, 543 Loader

Revised Oct. 94
4. Pull the ring on the cable [A] while the second
person lifts the operator cab a small amount until the
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–MainFrameSectionPages1a–1b
A
lock mechanism is released.
5. Both persons must slowly lower the operator cab by

holding the bottom of the operator cab and grab the
handles (Page 5–1 [C]).
6. Install the two nuts and washers (Page 5–1 [B]).

Tighten the nuts to 40–50 ft.–lbs. (54–69 Nm)
torque.
7. Connect the wiring harness behind the seat (Page

5–1 [A]).
8. Remove the LIFT ARM SUPPORT DEVICE while B–04039

the second person is in the operator seat.
B
Lowering The Operator Cab
20001 & Above: 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.
Install bolt and washer from underneath the fender.

Install the plate and nut.
Tighten the nuts to 40–50 ft.–lbs. (54–68 Nm) torque.
5–1.3 Jumper Start Switch

P–01704
The tool listed will be needed to do the following
procedure:
C
MEL1138A – A Jumper Start Switch
The short wire harness assembly is required when the
operator cab is in the raised position for service and the
serviceman needs to start the engine. The wire harness
connectors separate when the operator cab is tilted back.
Install the short wire harness [C] into the engine wire
harness of the loader. This jumper start switch is required
when the serviceman is adjusting the steering linkage,
checking the charge pressure and making
hydraulic/hydrostatic pump tests.
B–04459
540, 543 Loader

Revised Oct. 94
5–1.4 Removing The Operator Cab
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–MainFrameSectionPages2
When raising the operator cab or working on

the loader, put jackstands under the loader
frame so there is no danger of the loader falling
and causing personal injury.
1. Stop the engine.

B–09782
2. Raise the operator cab (See Paragraph 5–1.1).
3. Install a bar at the balance point and fasten a chain Early Models
hoist as shown [A]. B
4. Remove the bolts and remove the spring blocks that
hold the springs in position [B].

B–04542
540, 543 Loader

Revised Oct. 94
5–1.5 Removing The Gas Cylinder
A
Cylinder contains high pressure gas. Do not

open. Opening cylinder can release rod and
cause injury or death.
W–2113–0288
5. Remove the retainer clip from the upper gas cylinder

pivot pin (both sides) [A].
B–08511
6. Remove the upper pivot pin for the gas cylinder

(both sides).
B
Installation: Install the lower pivot pin first, use a
screwdriver to hold the gas cylinder and install the top
pivot pin [B].

B–08510
7. Remove the retainer clip at the lower gas cylinder

pivot pin (both sides) [C]. C
B–09889
8. Remove the lower pivot pin (both sides) [D].

D
B–09890
540, 543 Loader

147 of Oct.
Revised 322 98 –5–2a– Service Manual
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–MainFrameSectionPages2a–2b
540, 543 Loader

9. Remove the nuts from the pivot bolts (Fig. 5–9).
10. With the chain hoist tight, using a punch, remove the pivot bolts from the
operator cab pivot brackets (Fig. 5–10).
11. Using a pry bar, pry the springs out of the operator cab (Fig. 5–11).
12. Remove the operator cab with the chain hoist.
5–1.6 Installing The Operator Cab
1. Raise the operator cab, with a chain hoist, over the loader.
2. Make alignment of the spring ends and install them in the operator cab (Fig.
5–11).
3. Lower the chain hoist until the pivot bracket holes are in alignment.
4. Install the pivot bolts in the pivot brackets. B–04054

Fig. 5–9 Removing The Nut
5. Install the nuts and tighten to 25–35 ft.–lbs. (34–47 Nm) torque (Fig. 5–9).
6. Install the spring blocks. Install the bolts in the spring blocks and tighten to
65–70 ft.–lbs. (88–95 Nm) torque.
7. Remove the chain hoist from the operator cab.

8. Lower the operator cab (See Paragraph 5–1.2).
When raising the operator cab or

working on the loader, put
WARNING jackstands under the loader frame
so there is no danger of the loader
falling and causing personal injury.
B–04047
Fig. 5–10 Removing The Bolt
5–2 LIFT ARMS

5–2.1 Removing The Lift Arms
1. Stop the engine, activate the

hydraulic controls to release all
the hydraulic pressure.
2. Remove the Bob–Tach from the

lift arms (See Paragraph
5–3.1).
3. Fasten a chain hoist to the lift

arms as shown in figure 5–12.
B–04057 B–02801
Fig. 5–11 Operator Cab Spring Fig. 5–12 Installing The Chain Hoist
Revised Oct. 94
540, 543 Loader
4. Put a floor jack under the lift
arms (Fig. 5–13).
5. Raise the lift arms, with the floor

jack, until the pivot pins in the
rod end of the lift cylinders can
be removed.

from the rod end pivot pins (Fig.
5–14) (both sides).
7. Remove the pivot pins (Fig.

5–15). Be careful when
removing the pivot pins at the
lift cylinder. Put a support under
the cylinder to keep it from
falling when the pins are
removed.
B–04543 B–04392
8. Lower the lift arms and remove Fig. 5–13 Lifting Lift Arms With Floor Jack Fig. 5–14 Locknut And Bolts
the floor jack.

(Fig. 5–16) (both sides) from
the lift arm pivot pin.

10. Tighten the chain hoist.
Remove the pivot pins (Fig.
5–17) from the lift arms.
11. Raise the lift arms, with the

chain hoist and remove the lift
arms from the loader.
B–04393
Fig. 5–15 Removing Rod End Pin
5–2.2 Installing The Lift Arms
1. With a chain hoist, position the lift arms on the loader and make alignment
of the pivot pin holes in the lift arms and main frame.
2. Install the pivot pins in the main frame and the lift arms.
3. Install the bolt and locknut and tighten to 18–20 ft.–lbs. (24–27 Nm) torque
(Fig. 5–16).
B–04544
Fig. 5–16 Locknut And Bolt
540, 543 Loader

4. Remove the chain hoist and
chains from the lift arms.
5. Install the rod end of the lift

cylinder in the lift arms.
6. Install the pivot pin in the lift

cylinder.
7. Install the bolt and the locknut in

the pivot pin and tighten to
18–20 ft.–lbs. (24–27 Nm)
8. Install the Bob–Tach on the lift

arms (See Paragraph 5–3.4).
9. Remove the jackstands from

the loader frame. B–04545
Fig. 5–17 Removing Pivot Pins From The Lift Arms
5–3 BOB–TACH
5–3.1 Removing The Bob–Tach

1. Start the engine. Tilt the
Bob–Tach forward until the
front edge of the Bob–Tach is
on the floor (Fig. 5–18).
2. Stop the engine. Activate the

hydraulic controls to release the
hydraulic pressure from the
system.
3. Remove the locknut and bolt at

the rod end of the tilt cylinder
(Fig. 5–19).
B–05103
Fig. 5–18 Removing The Bob–Tach
4. Remove the pivot pin (Fig.

5–20) from the tilt cylinder rod B–05104
end.
Fig. 5–19 Locknut And Bolt
B–05105
Fig. 5–20 Removing The Pivot Pin
540, 543 Loader

5. Loosen the bolt 1 – 1–1/2 turns
(Do not remove) at the
Bob–Tach pivot pin (Fig. 5–21)
(both sides).
6. Remove the grease fitting at the

pivot pin (Fig. 5–22).
NOTE: The grease fitting at the

pivot pin must be
removed, because the
grease can cause a lock
and the pivot pin cannot
B–05106
be pushed into the
Bob–Tach frame. Fig. 5–21 Pivot Pin Bolt
7. Hit the bolt, with a hammer (Fig.

5–23) to start the pivot pin into
the Bob–Tach frame. This will B–05107
break the pin loose from the Fig. 5–22 Grease Fitting
tapered seat.
8. Remove the bolt and use a

punch to push the pivot pin into
the Bob–Tach frame.

9. Remove the Bob–Tach from the
lift arms.
B–05109
Fig. 5–23 Removing Pivot Pin
B–04871
Fig. 5–24 Removing The Pivot Pin

Bob–Tach
1. Put the Bob–Tach on the work

bench.
2. Remove the Bob–Tach pivot
pins (Fig. 5–24).
3. Remove the bolt at the

Bob–Tach lever (Fig. 5–25).
4. Use a punch and hammer to

remove the wedge and lever
assembly from the frame (Fig.
5–26).
B–05111 B–05112
Fig. 5–25 Removing The Lever Bolt Fig. 5–26 Removing Wedge Assembly
540, 543 Loader

5. Put the wedge and lever
assembly in the vise. Remove
the bolt from the lever (Fig.
5–27).
6. Remove the block from the

wedge bolt (Fig. 5–28).
B–04553 B–04554
Fig. 5–27 Lever Bolt Fig. 5–28 Wedge Block
7. Remove the nut (Fig. 5–29) and

remove the spring from the bolt.
8. Remove the plastic guides from

the Bob–Tach frame (Fig.
5–30).
9. Clean and inspect all the parts

for wear and damage. Replace

the parts as needed.
B–04556 B–04875
5–3.3 Assembly Of The Bob–Tach
Fig. 5–29 Removing The Nut Fig. 5–30 Removing Plastic Guides
1. Install the spring on the wedge

bolt. Install the nut (Fig. 5–31).
2. Install the block on the wedge 6.09–6.21”

bolt. Turn the block down until (155–158 mm)
there is 6.090 – 6.210 inches
(155–158 mm) from the center
of the lever bolt hole to the top
of the wedge where the spring
seats (Fig. 5–32).
3. Tighten the nut to 65–70 ft.–lbs.

(88–95 Nm) torque to lock the B–04556 B–04554
block into position.
Fig. 5–31 Installing The Spring Fig. 5–32 Installing The Block
4. Install the lever and bolt and

tighten the bolt to 25–28 ft.–lbs.
(34–38 Nm) torque (Fig. 5–33).
5. Install the new plastic guides in

the Bob–Tach frame (Fig.
5–34).
B–04557 B–04875
Fig. 5–33 Tightening The Lever Bolt Fig. 5–34 Installing Plastic Guides
540, 543 Loader

6. Using a punch and hammer,
install the wedges and lever
assembly in the Bob–Tach
frame (Fig. 5–35).
7. Install the spring behind the

lever. Install the bolt and tighten
to 25–28 ft.–lbs. (34–38 Nm)
8. Install the pivot pin in the

Bob–Tach frame (Fig. 5–37),
the tapered area facing out.
B–05111
Fig. 5–36 Tightening Lever Bolt
B–05112
Fig. 5–35 Installing Wedge And Lever
Assembly

B–04871
5–3.4 Installing The Bob–Tach
1. Put the Bob–Tach between the

lift arms.
2. Using a punch, push the pivot

pin into the lift arms (Fig. 5–38)
from the grease fitting hole.
B–04889
3. Install the bolt and washer into
the pivot pin and tighten to Fig. 5–38 Installing Pivot Pin
125–140 ft.–lbs. (170–190 Nm)
4. Install the grease fittings and

tighten (Fig. 5–40).
5. Lubricate the pivot pins with

grease.
6. Put the floor jack under the

Bob–Tach frame.
7. Lift the Bob–Tach frame, with

the floor jack, until the tilt
cylinder rod end hole is in
alignment with the holes in the B–05106 B–05107
Bob–Tach frame.
Fig. 5–39 Tightening The Bolt Fig. 5–40 Installing Grease Fitting
Revised Oct. 94
540, 543 Loader
8. Install the rod end pin in the
Bob–Tach frame (Fig. 5–41).
9. Install the bolt and locknut and

tighten (Fig. 5–42). Lubricate
the grease fitting.
B–05113

5–4 REAR DOOR
5–4.1 Removing The Rear Door
B–05104
Fig. 5–42 Tightening The Bolt
Keep the rear door closed except for

service. Make sure you close the
WARNING door and fasten the latch tightly
before you operate the Bobcat
loader.
2. Install a chain hoist on the rear

door (Fig. 5–43).
NOTE: On the 540 loader the oil

cooler hoses will have to
be disconnected before
you can remove the rear
door (See Paragraph
2–8.1, Page 2–23).
3. Remove the hinge pins (Fig.

5–44).
4. Remove the rear door from the

loader.
B–12408
Fig. 5–43 Installing The Chain Hoist
5–4.2 Installing The Rear Door
1. Install the rear door on the

loader.
2. Make alignment of the hinges

and hinge brackets and install B–05772
the hinge pins.
3. Remove the chain hoist.
B–12392 B–04101
5–4.3 Adjusting The Rear Door Fig. 5–44 Hinge Pins Fig. 5–45 Door Latch Nut
Latch
1. Loosen the set screw (Fig. 5–45, Inset).
2. Loosen the nut at the latch bolt (Fig. 5–45).

3. Turn the latch bolt in or out to get the correct adjustment (Fig. 5–46).
5. The rear door must contact the main frame at the bottom and top with the
lever in the position as shown in figure 5–47.
6. It will take about 50 lbs. of

pressure to push the lever down
into locked position if the rear
door is adjusted correctly.
B–04099
Fig. 5–47 Closing The Rear Door
5–5 FUEL TANK

B–04571
5–5.1 Removing The Fuel Tank Fig. 5–46 Latch Bolt
1. Raise the lift arms and install a lift arm support devise (See Paragraph 1–12,
Page 1–18).
2. Raise the operator cab (See Paragraph 5–1.1).
3. Disconnect the wire from the connector in the operator cab (Fig. 5–48).
B–04886
Fig. 5–48 Disconnecting Sender Wire

4. Put the wire in the tank area
(Fig. 5–49).
5. Remove the fuel line(s) at the

fuel tank (Fig. 5–50).
6. Remove the nut which holds the

fuel tank strap in position (Fig.
5–51).
7. Remove the fuel tank from the

loader (Fig. 5–52).
B–04882 B–05981
Fig. 5–49 Fuel Sender Wire Fig. 5–50 Disconnect The Fuel Line
5–5.2 Installing The Fuel Tank
1. Put the fuel tank in its correct

location.

2. Connect the strap to the bolt
and install the nuts and tighten
(Fig. 5–51).
3. Connect the fuel line at the

tank.
4. Connect the sender wire (Fig.

5–48).

Paragraph 5–1.2).
6. Remove the lift arm support B–04894 B–04895

device Paragraph 1–12, Page
1–18) and lower the lift arms. Fig. 5–51 Remove The Holddown Strap Fig. 5–52 Removing The Fuel Tank
5–6 SEAT BAR

5–6.1 Removal And Installation
1. Remove the seat bar pivot bolt
(both sides) (Fig. 5–53).
2. Remove the bolt, spacer,

washer, spring and plate (both
sides) (Fig. 5–54).
NOTE: To remove the seat bar it

may be necessary to pull
the seat bar together to get
the clearance at the
operator cab.
B–08880
Fig. 5–53 Removing Seat Bar

5–7 SEAT BAR SYSTEM
The seat bar system has a pivoting
seat bar with arm rests and has
spring–loaded latches for the lift and
tilt control pedals. The operator
controls the use of the seat bar. The
seat bar in the down position keeps
the operator in the seat and unlocks
the foot pedals. When the seat bar is
up, the lift and tilt pedals are locked in
neutral position.
D–01709
Fig. 5–54 Seat Bar Assembly
5–7.1 Seat Bar Inspection
1. Sit in the seat and fasten seat belt snugly.

2. Pull the seat bar all the way down and start the engine.
3. Operate each foot pedal to check both the lift arm and tilt (bucket) functions.
Put the bucket horizontal and raise the lift arms until the bucket is about two
feet (600 mm) off the ground.
4. Raise the seat bar. Try to move each foot pedal. Pedals must be firmly locked
in the neutral position. There must be no motion of the lift arms or tilt (bucket)
when the pedals are pushed.
5. Pull the seat bar down, lower the lift arms all the way and put the bucket flat
on the ground.
6. Stop the engine. Engage the brake. Raise the seat bar and operate the foot
pedals to be sure that the pedals are firmly locked in the neutral position.
Unfasten the seat belt.
5–7.2 Seat Bar Maintenance
1. Clean debris or dirt from moving parts.
2. Inspect linkage bolts and nuts for tightness 25–28 ft.–lbs. (34–38 Nm)
torque.
3. Use general purpose grease to lubricate the seat bar pivot points at each
side of the cab.
4. If seat bar system does not function correctly, check for free movement of
each linkage part. Check for excessive wear. Replace parts that are worn,
bent or broken.
Added Aug. 85 540, 543 Loader

5–8 PEDAL LOCK LINKAGE
5–8.1 Adjustment
1. The pedal lock linkage must be
free to lock the pedals (Fig.
5–55).
2. The tab must go into the slot at
the lock (Fig. 5–56).
3. If not, loosen the bolts (Fig.

5–56, Item 1) and adjust the tab
for engagement.
D–01548
4. Pedal must be in neutral for Fig. 5–55 Pedal Lock Linkage
adjustment.
5. Tighten the bolts (Fig. 5–56,

Item 1) to 25 ft.–lbs. (34 Nm)
torque.
Pedal control linkage must be

adjusted so that seat bar system
WARNING locks the lift and tilt control pedals
when seat bar is up. Failure to obey
warnings can cause injury or death.

1
B–04043
Fig. 5–56 Pedal Lock Engaged
5–9 REAR WINDOW

5–9.1 Installing Rear Window
1. Put moulding in the opening in

rear of cab. Groove for bead
must be toward inside of cab.
2. Put window in moulding.
3. Insert eye of special tool

(MEL1211) into groove of
moulding. Use liquid soap to
help tool slide. B–08280
Fig. 5–57 Bead Installing Tool
4. Feed cord in from front of the
tool eye (Fig. 5–57).
5. Slide the tool forward, following

groove in the moulding, while
feeding the cord into the tool
eye (Fig. 5–58).
6. Do not stretch cord.
7. When completed, cut excess

cord, leaving a small overlap.
Push overlap into the groove to
form a tight joint.
B–08281
Fig. 5–58 Bead Installation
Added Aug. 85 540, 543 Loader

540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–MainFrameSectionPages3–14
540, 543 Loader

ELECTRICAL SYSTEM
Paragraph Page
Number Number
ALTERNATOR SYSTEM (540) . . . . . . . . . . . . . . . . . . . . . . . . . 6–6 6–6
ALTERNATOR SYSTEM (543) . . . . . . . . . . . . . . . . . . . . . . . . . 6–7 6–6
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3 6–3

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . 6–2 6–2
STARTER (540) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8 6–11

STARTER (543) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9 6–12
WIRE HARNESS FOR THE ENGINE . . . . . . . . . . . . . . . . . . . 6–5 6–5

WIRE HARNESS FOR THE OPERATOR CAB . . . . . . . . . . . 6–4 6–4

ELECTRICAL
SYSTEM

WARNING the warnings and instructions at the
death.
540, 543 Loader

540, 543 Loader

163 of 322
164 of 322
165 of 322
166 of 322
167 of 322
168 of 322
169 of 322
170 of 322
171 of 322
172 of 322
173 of 322
174 of 322
175 of 322
176 of 322
6 ELECTRICAL SYSTEM
The following troubleshooting chart is provided for
assistance in locating and correcting problems. Many of
the recommended procedures must be done by Instructions are necessary before operating or
authorized Bobcat Service Personnel only. servicing machine. Read Operation &
Maintenance Manuals, 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–2003–1289
PROBLEM CAUSE
Battery loses charge. 1, 2, 3, 4, 5

Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
1. Alternator belt is loose or damaged.

2. Battery connections are dirty or loose.
3. Battery is defective.
4. The ground is not correct in the electrical system.

5. The alternator has a defect.
6. Engine seizure.
7. Starter has a defect.

8. Wiring or solenoid has a defect.
9. Fuse has a defect.
540, 543 Loader

177 of 322
6–2 ELECTRICAL SYSTEM
INFORMATION
6–2.1 Electrical Circuitry
There are two (2) basic circuits in the
electrical system of the loader:
1. Charging Circuit
a. Alternator
b. Internal Regulator
c. Voltmeter
d. Battery
2. Starting Circuit A–02740
a. Starter Fig. 6–1 Battery Warning – Do Not Smoke Near The Battery
b. Solenoids
c. Battery
The ignition switch must be turned ON to activate these circuits.
6–2.2 Safety Procedures For The Batteries
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
WARNING eye contact get prompt medical
attention and wash eye with clean,
cool water for at least 15 minutes.
If electrolyte is taken internally drink
large quantities of water or milk! DO
NOT induce vomiting. Get prompt
medical attention.
W–2065–1296
1. When connecting extra battery for ‘‘jump’’ start always make the last
connection (negative cable) to the engine (never at the battery),
2. When remove the ‘‘jump’’ start cables, always remove the negative cable
from the engine first.

engine frame.
or damaged battery. Warm battery to
WARNING 60°F. (16°C.) before connecting to a
serious injury.
W–2066–1296
The vent caps for the batteries of this loader must not be removed when the
batteries are charges. The battery has a vent cap which will decrease the
possibility of the battery being exploded by a external spark. Always disconnect
the ground cable from the batteries before charging the battery in the loader.
The battery fluid in the battery with a low charge may freeze solid in cold weather.
If the battery is frozen it must be thawed in a heated room before the battery is
connected to another battery or charger in order to avoid explosion of the frozen
battery.
540, 543 Loader
17898
6–2.3 Precautions For The Alternator
1. DO NOT reverse the battery connections. This is a
negative ground system only.
2. Connect the battery correctly.
3. DO NOT polarize the alternator.
4. DO NOT ground any of the wires from the alternator.
B–05951
Fig. 6–2
Damage to the alternator can occur if:
• Engine is operated with battery cables
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.
I–2023–1285

6–3 BATTERY
6–3.1 Removing The Battery
B–05952
NOTE: The procedure is the same for the 543B.
Fig. 6–3
1. Stop the engine. Open the rear door.
2. Disconnect the cables from the battery (Fig. 6–2 or
Fig. 6–3).
NOTE: Always disconnect the negative cable first to
prevent sparks.
3. Remove the nuts and bolts from the holddown
clamps and remove the holddown clamps.
4. Remove the battery and battery bracket from the

loader (Fig. 6–4 or Fig. 6–5).
B–05953
Fig. 6–4
B–05954
Fig. 6–5
540, 543 Loader
179 of Oct.
6–3.2 Installing The Battery
1. Put the battery bracket in the

loader and locate it in the correct
position.
2. Install the battery into the battery

bracket (Fig. 6–4 or Fig. 6–5).
2
3. Install the battery holddown clamp
and tighten the nuts to 30–50
in.–lbs. (3,4–5,5 Nm) torque.
1
4. Connect the positive cable first B–04696
and tighten the clamp.
Fig. 6–6 Wire Harness Connector
5. Connect the negative cable and
tighten the clamp.
6. Close the rear door. B–04491

Fig. 6–7 Wire Harness Clip
6–4 WIRE HARNESS FOR THE
OPERATOR CAB
6–4.1 Removing The Wire Harness
For The Operator Cab

1. Open the rear door. Disconnect
the negative cable from the
battery.
2. Disconnect the wiring harness

connector behind the seat (Fig.
6–6).
3. Disconnect the connector at the

fuel sender wires (Fig. 6–7, Item
1).
4. Remove the harness clip (Fig.

6–7, Item 2).
5. Remove the rear light from the B–04504 B–04497

mounting. Disconnect the wires Fig. 6–8 Rear Light Fig. 6–9 Harness Clip
from the rear light (Fig. 6–8).
6. Remove all the harness clips on

the operator cab (Fig. 6–9).
7. Remove the dash panel nuts and

bolts (Fig. 6–10).
B–04498
Fig. 6–10 Dash Panel Bolts & Nuts
540, 543 Loader

18098
8. Remove the front lights from the mounting. Disconnect the wires from the
front lights (Fig. 6–11).
9. Pull the dash panel down and remove the wires for the front lights from the
rubber grommets (Fig. 6–12).
10. Remove the dash panel from the loader and put it on the work bench.
11. Locate the new wiring harness along side the dash panel.
12. Disconnect a wire from the dash panel, find the wire in the new wiring
harness and connect it to the same location.
NOTE: Also see the WIRING DIAGRAM at the front of the Electrical Section.
6–4.2 Installing The Wire Harness For The Operator Cab
1. After the new wiring harness is installed in the dash panel, make sure that B–04495
all terminals are tight. Fig. 6–11 Front Light
2. Install the dash panel in the loader.
3. Put the wires for the front lights through the rubber grommets (Fig. 6–12).

4. Put the dash panel in the correct position. Install the bolts and nuts and
tighten.
5. Connect the wires to the front lights (Fig. 6–11). Install the front lights in the
rubber mounting.
6. Install the harness clips along the side of the operator cab (Fig. 6–9).
7. Put the wires for the rear light through the rubber grommet and connect the
wires to the rear light (Fig. 6–8).
8. Connect the wires to the fuel sender (Fig. 6–7, Item 1).
9. Connect the wire harness connectors (Fig. 6–6).
10. Connect the negative cable to the battery. B–04501

Fig. 6–12 Rubber Grommets
6–5 WIRE HARNESS FOR THE ENGINE

It will be easier to install the new wiring harness on the engine if the engine is
removed from the loader (See Section 7A or 7B for engine removal).

When installing a new wiring harness
on the engine, locate the new wiring
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–ElectricalSectionPages1–6
harness by the engine. Disconnect a RED

wire from the engine (Example: Oil RED
Pressure Sender), find the wire in the
new wiring harness and connect it to
the same location. BLACK
BLACK
NOTE: Also see the WIRING

DIAGRAM at the front of Instrument
the Electrical Section. Panel
ALTERNATOR +BAT.
FLYWHEEL –BAT.
Fig. 6–13 Alternator Wiring Diagram
6–6 ALTERNATOR SYSTEM (540)

6–6.1 Checking The Alternator
Before running the engine or
checking the alternator or
rectifier/regulator, read the
IMPORTANT statements below. BLACK (AC)
To Alternator BLACK (AC)

To Alternator
RED RED
To Alternator To Alternator
RED To
BLACK Instrument Panel
–BAT. RED To Battery
NEG.
Fig. 6–14 30 Amp Rectifier/Regulator
1. The battery polarity must be

correct; negative (–) battery
cable must be connected to
ground.
2. The rectifier/regulator must
have a common ground with
the engine and battery.
3. Make sure that no fuses,
resistors or wires smaller than
#10 AWG are connected
between the battery and
IMPORTANT rectifier.
4. If any arc welding is done,
disconnect the wire at terminal
marked BATT. NEG on the
rectifier.
5. When charging the battery,
disconnect the
battery–to–regulator wire.
6. Do not run the engine when the
battery is disconnected from
the alternator system.
7. Be sure that AC wires are not
grounded.
540, 543 Loader

PROBLEM CAUSE TEST AND CORRECTION
No Output A. Windings in A. Stop the engine and remove the four input
Stator are wires from the rectifier/regulator. Check
Defective the resistance on the RX1 scale of an
ohmmeter.
Test #1 – Connect the two ohmmeter wires
to the two red wires which were
disconnected from the rectifier/regulator.
The ohmmeter must show approximately
2.0 ohms resistance.
Test #2 – Connect the two ohmmeter wires
to the two black wires which were
disconnected from the rectifier/regulator.
The ohmmeter must show approximately
0.1 ohms resistance.
B. Diode(s) in B. Stop the engine. Connect a low voltage
Rectifier continuity tester (3–volt) between
are BATT–NEG and one of the AC terminals;
Defective then reverse the connection. The lamp of

the tester must turn ON when connected
one way and OFF when connected the
other way. Repeat this procedure on the
other AC terminal. The lamp of the tester
must turn ON when connected one way
and OFF when connected the other way. If
the lamp stays ON when connected both
ways or OFF when connected both ways,
the diode must be replaced.
No Charge A. Regulator A. Remove the red wire from the REG

(When Winding is terminal on the rectifier/regulator. Remove
30–Amp Defective the wire from the +BATT terminal of the
min. load is rectifier/regulator and connect an ammeter
applied to between this wire and the +BATT terminal.
Battery) Start the engine and operate at full RPM.
With the REG wire disconnected, the
alternator will charge at full output
(30–Amps). Replace the stator if output is
not 30–Amps.
Full Charge A. Regulator A. Remove the two red wires from the
No Winding is rectifier/regulator which go to the
Regulation Defective alternator, and connect these wires
together. Remove the wire from the +BATT
terminal of the rectifier/regulator and
connect an ammeter between this wire and
the +BATT terminal. Start the engine and
run at full RPM. If the stator is good, the
ammeter will show a 4–Amp charge.
B. Regulator B. If the stator is good, the defect is in the

is Defective regulator part of the rectifier/regulator.
Replace the rectifier/regulator.

6–6.2 Replacing The Stator
1. Remove the engine blower

housing.
2. Hold the flywheel and remove

the nut (Fig. 6–14a).
3. Use a puller to remove the

flywheel from the engine (Fig.
6–15).
4. Remove the bolts which hold

C–02336
the stator to the engine (Fig.
6–15). Fig. 6–14a Removing Flywheel Nut
5. Install the new stator and tighten the bolts.

C–02334
6. Install the flywheel and tighten the nut to 115 ft.–lbs. (156 Nm) torque.
Fig. 6–15 Removing The Flywheel
7. Install the blower housing.
6–7 ALTERNATOR SYSTEM (543)

6–7.1 Adjusting The Alternator Belt
Bolts
B–02881
Fig. 6–16 Removing The Stator

6–7.1 Adjusting The Alternator Belt (Cont’d)
A
2. Remove the belt shield from the engine [A].
3. Loosen the top bolt on the alternator mounting

bracket.
4. Loosen the adjusting bolt.
B–05847
5. Move the alternator to get the correct adjustment on

the belt of 0.250 inch (6,35 mm) movement with 5
lbs. of pressure between the pulleys [B].
B
6. Tighten the adjusting bolt.
7. Tighten the stop mounting bolt.

B–05849

6–7.1 Adjusting The Alternator Belt (Cont’d)
A Rear View Alternator
New 6661611
Test the New Style Alternator as follows:
a. Alternator Output Test
b. Rectifier (Diode) Test
c. Alternator Regulator Test
6–7.1a Alternator Output Test (New Style)
MC–01813
Put jackstands under the front axles and rear
corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or B 2
death.
W–2017–0286
Lift and block the loader. 1
Disconnect the negative (–) cable from the battery.

Disconnect the red wire (Item 1) [B] from the alternator.

Connect the wire to the negative (–) side of the ammeter.
Connect the positive (+) side of the ammeter to the output
terminal on the alternator (Item 2) [B].
Disconnect the fuel stop solenoid connector. P–01360
Connect the negative (–) cable to the battery.

Crank the engine for 30 seconds to discharge the battery. C Output
Terminal
Connect the fuel stop solenoid, start the engine and run
at 2600 RPM.
The ammeter reading should be between 45 & 55 amps.
@2600 RPM.
If the reading is low, remove the screws and pull the
regulator cover away from the alternator. 1
6–7.1b Rectifier (Diode) Test (New Style)

Regulator
The alternator is removed from the loader for clarity Terminal
P–01304
purposes [C].
Disconnect the negative (–) cable from the battery.
Install the wires in their original location on the back of the
alternator.
Connect a jumper wire (Item 1) [C] to the alternator output
terminal and the regulator terminal.
Connect the battery negative (–) cable.
Start the engine and run at 2600 RPM.
If the reading is within 45–55 amps. at 2600 RPM replace
the rectifier (diode) assembly or replace the alternator.
If the reading is low, do the Alternator Regulator Test.

ALTERNATOR (Cont’d)
6–7.1c Alternator Regulator Test (New Style)
A
Negative
When an engine is running in an enclosed

area, fresh air must be added to avoid
concentration of exhaust fumes. If the engine Positive
is stationary, vent the exhaust outside.
Exhaust fumes contain odorless, invisible
gases which can kill without warning. P–01308
W–2050–1285
Connect the positive (+) voltmeter lead to the positive (+)

B
battery terminal [A].
Connect the negative (–) voltmeter lead to the negative
(–) battery terminal [A]. Ground
Stud
Start the engine and run at 1500–2000 RPM.

The voltmeter should read between 13.9–14.7 volts.
If the reading is low stop the engine and disconnect the
battery negative (–) cable.
Brush 1
Terminal
The alternator is removed from the loader for clarity P–01364
purposes [B].
Remove the wires from the back of the alternator.
Remove the regulator cover from the back of the
alternator.
Install the wires on the back of the alternator.
Connect a jumper wire (Item 1) [B] from the brush
terminal to the ground stud.
Connect the negative (–) battery cable and start the
engine. Run at 1500 RPM.
If the voltmeter reading is 14.5 or above replace the
regulator.
If the voltmeter reading is below 14.5, repair or replace the
alternator.
Revised Oct. 94
540, 543 Loader
187 of 322 –6–6e– Service Manual
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–ElectricalSectionPages6a–6f
540, 543 Loader

188 of 322 –6–6f– Service Manual
6–7.2 Checking The Alternator (Early Models) No. 2
A No. 1 Terminal
Terminal
Bat
Terminal
Lift the loader and put jackstands under the

loader frame so there is no danger of the loader
To check the wiring harness use the following procedure: Test Hole
B–02113
1. Turn the key switch to the ON position.
2. Connect a voltmeter between the ground and the

No. 1 terminal of the connector plug [A] and check
the voltage.
3. Connect a voltmeter between the ground and the

No. 2 terminal of the connector plug [A] and check
the voltage.
4. Connect the voltmeter between ground and the BAT

terminal with the wire connected [A] and check the
voltage.
5. If any of the tests in steps 2, 3 &4 show zero voltage,

the wiring has an open.
6. Find the open in the wiring, make repair and check

the voltage again.

To check the alternator output, use the following
procedure:
A Test Hole
2. Disconnect the negative cable from the battery.
3. Disconnect the BAT connection at the alternator

and connect it to one connector of an ammeter.
Connect the other side of the ammeter to the BAT
terminal of the alternator.
4. Connect the negative cable at the battery.
5. Make sure the fuel shutoff control is in the OFF A–02211

position. B–02113
6. Turn the engine, with the starter, for 30 seconds to

lower the charge in the battery. B
7. Move the fuel shut off to the ON position. Start the
engine and run at full RPM.
8. The ammeter reading must be within 10% of the

rated amperage (which is 37 amps. at 2750 RPM).
9. If the reading is correct, the alternator is good. If the

reading is more or less than 10% of rated amperage,
check the regulator.
To check the regulator, use the following procedure:

B–05847
1. Use Steps 2 thru 7 for alternator output.
2. Put a small screwdriver in the test hole [A].

C
3. If the ammeter is within 10% of rated amperage
(which is 37 amps at 2750 RPM) the regulator is
good. If the reading is not within 10% of rated
amperage, check the diode trio, rectifier, stator or
rotor (See Paragraph 6–7.4, Page 6–9).
B–05182

Parts Identification (New Style)
A 2
3
8
1. Nut 7
2. Pulley 5
3. Fan 4 6
4. Bolt
5. Case Half (Front)
6. Bearing
7. Rotor
8. Stator
9. Rectifier (Diode) 12
10. Case Half (Rear)
11. Condenser Assy.
12. Strap 13
13. Regulator
14. Brush
15. Cover
11 14
9 10

15
D–01760
6–7.2a Disassembly And Assembly (New Style)

Disassemble the alternator as shown.
Remove the regulator cover and regulator. B
Remove the four bolts holding halves together.
Pry the halves apart (use a press if needed).
Use a soft jaw vise to hold rotor while removing pulley nut.
Remove front case half from the rotor using a plastic
hammer or press.
Unsolder the stator leads from the rectifier. Remove the
stator.
Stator Continuity Test
P–01369
Use an ohmmeter to test the stator.
Touch the probes to two of the bare stator wires [B]. C
Move one of the probes to the third wire.
The readings should be the same.
If there is no continuity, replace the stator.
Stator Ground Test
Touch one probe to a bare stator lead and the other probe
to the bare metal surface of the stator [C].
There should be no continuity.

Replace the stator if there is continuity. P–01365

Rotor Continuity Test
A
Touch the probes to the slip rings [A].
The ohmmeter should read between 3.065–3.385 ohms.
If there is no continuity replace the rotor.
P–01365
Rotor Ground Test

Touch one probe to one of the slip rings and the other
B
probe to the rotor shaft [B].
There should be no continuity.
Replace the rotor if there is continuity.

P–01378
Rectifier Continuity (Diode) Test
NOTE: In the diode test there should be continuity in

C
one direction only. If the diode being tested
shows no continuity or continuity in both
directions, replace the rectifier assembly.
Touch the probes to the terminals of each diode and read

the meter [C].
Reverse the probes to check the diode in the other
direction.
There should be continuity in one direction only.
P–01373
Touch one probe to the diode and the other probe to the
connected heatsink and read the meter [D]. D
direction.
Touch On
Bottom Heat Sink
P–01370
Rectifier Continuity (Diode) Test (Cont’d)
A
Touch one probe to the diode and the other probe to the
connected heatsink and read the meter [A].
direction.
Touch On Center
Heat Sink
P–01390
Reverse the order of disassembly.

B
Do not assemble the rear case half.
Place the rotor in soft jaws when tightening the shaft nut.
Tighten to 50 ft.–lbs. (68 Nm) torque [B].
Install the rear case half and the remaining parts.

P–01808

540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–ElectricalSectionPages8a–8d
540, 543 Loader

6–7.3 Removing The Alternator (Early Models)
A
2. Disconnect the negative cable from the battery.
3. Remove the engine belt shield from the engine (See

Page 6–8, [B]).
4. Remove the adjustment bolt.
5. Remove the belt.

Check for Shorts
6. Remove the top bolt from the mounting bracket. and Opens
A–01857
7. Remove the alternator from the mounting bracket.
8. Disconnect the connector from the alternator and Check for Check for
the wire. (See Page 6–8, [C]). B Opens Grounds
6–7.4 Repairing The Alternator (Early Models)
1. Put a mark across the alternator case for correct

assembly.

2. Remove the pulley from the alternator shaft.
3. Remove the four bolts that hold the case halves
together.
4. Use a screwdriver to pry the case halves apart. Check for
Opens
5. Remove the rotor from the housing. B–02108
6. Remove the three nuts that hold the stator wires to

the housing. Remove the stator.
C
7. Disconnect the diode trio.
8. Connect an ohmmeter between one slip ring and the
shaft. There must be maximum resistance [A].
9. Connect the ohmmeter between both slip rings.
There must be 2.3 to 3 ohms of resistance. If there
is not, there is a defect in the rotor [A].
10. Connect a test light between the center wire and one
of the outside wires on the stator [B]. If the light does
not come ON there is a defect.
11. Connect the test light between the center wire and
the other side outside wire [B]. If the light does not
come ON there is a defect. A–02382
12. Connect the test light between one of the wires and
the stator frame [B]. If the light comes ON there is
a defect.
13. Connect a D.C. test light between the single
connection and on one of the three connections [C].
Connect the tester in the opposite direction. The
light must come ON in one direction, but not in the
other direction. Do not use high voltage to check diode trio or
14. Do Step 13 for the other diodes. rectifier.
15. Connect the test light between the center
connections and each outside connection. If the
light comes ON on either side, there is a defect.
16. Remove the rectifier from the alternator.

17. Connect a test light between one connection and
the insulated heat sink [A]. Connect the test light in A Insulated
Heat Sink
the other direction. The light must be ON in one
direction, but not in the other direction.
18. Connect the test light between the same connection

and ground heat sink [A]. Connect the tester in the
other direction. The light must come ON in one
direction, but not in the other direction.
19. Do steps 17 & 18 on both the other connections. If

any of the tests are bad, replace the rectifier.
20. Install the rectifier. Grounded

Heat Sink
21. If the regulator is removed, make sure when B–02102
installing it to replace the two insulated washers and
spacers [B].
22. Install the diode trio.

B Insulated Washers
23. Install the stator and connect the wires.
24. Install the new brushes and put a piece of straight

wire through the housing to hold the brushes in the
up position [C].

25. Install the rotor and remove the wire.
26. Put the case halves together and install the bolts
and tighten.
27. Install the sheaves and tighten the nut to 50 ft.–lbs. B–02128
(68 Nm) torque.
6–7.5 Installing The Alternator (Early Models)

C
1. Connect the wire at the alternator [D].
2. Put the alternator in the mounting bracket and install

the top bolt.
3. Install the belt.
4. Install the adjusting bolt. Do not tighten.
5. Adjust the alternator belt for the correct tension (See

Paragraph 6–7.1) B–02097
6. Install the belt shield.
7. Connect the negative cable at the battery. D
B–05182

6–8 STARTER (540)
6–8.1 Checking The Starter
1. Make sure the ignition is in the OFF position. Make sure the battery has a
full charge and the cable connections are clean and tight.
2. Connect the jumper wire between the solenoid connection (Fig. 6–30, Item
1) and the BAT connection (Item 2). If the starter turns but the engine does
not, the defect is in the starter drive. If the starter does not turn, go to step 1
3.
3. Connect a jumper wire between the M connection (Fig. 6–30, Item 3) and the 2
BAT connection (Item 2). If the starter turns the defect is in the solenoid.
2
6–8.2 Removing The Starter
B–05183
Fig. 6–30 Starter Solenoid (540)
2. Disconnect the battery cables, the negative cable first.
3. Remove the battery from the loader.
4. Remove the wire from the starter (Fig. 6–31).

5. Remove the starter bolts (Fig. 6–32).
6. Remove the starter from the engine.
6–8.3 Repairing The Starter

Starter
1. Pull the rubber cap off the end Bolts
of the starter shaft.
2. Use two wrenches to remove

the nut on the end of the starter
3. Remove the starter drive (Fig.

6–34).
4. Put a mark on the side of the B–05187 B–05189

starter housing and end plates Fig. 6–31 Starter Wires Fig. 6–32 Starter Bolts
for easier assembly.
B–02839 B–02862
Fig. 6–33 Starter Drive Nut Fig. 6–34 Starter Drive Parts
540, 543 Loader

5. Check the condition of the brushes. If the brushes are less than 0.3125 inch
(8 mm) in length, install new brushes (Fig. 6–35).
Brushes
6. Check the commutator (Fig. 6–36) and check the armature in the growler.
7. Check all the parts of the starter for damage. Add lubricant to the bushings
and assemble the starter parts.
NOTE: DO NOT put lubricant on the starter drive splines.
Brushes
B–02878
Fig. 6–35 Checking The Brushes
6–9 STARTER (543)

6–9.1 Checking The Starter
1. Make sure the ignition is in the OFF position. Make sure the battery has a
full charge and the cables are clean and tight.

2. Connect a jumper wire between the S connection and BAT connection (Fig.
6–37). If the starter turns, but the engine does not turn, the defect is in the
starter drive. If starter does not turn go to Step 3.
3. Connect a jumper wire between the M connection and the BAT connection B–02860
(Fig. 6–38). If the starter turns, there is a defect in the solenoid. Fig. 6–36 Checking Commutator
6–9.2 Removing The Starter

Jumper Wire Jumper Wire
Solenoid
1. Stop the engine. Open the rear
door. Bat Bat
S S
M M
2. Disconnect the cables from the
battery, negative cable first.
Cranking Cranking
3. Remove the battery from the Motor Motor
loader.
A–01992 A–01991
Fig. 6–37 Checking Starter Fig. 6–38 Checking Starter
4. Remove all the wires from the

starter solenoid (Fig. 6–39).

starter mounting bracket (Fig.
6–40).
B–05955 B–05956
Fig. 6–39 Starter Solenoid Fig. 6–40 Starter Mounting Bracket
540, 543 Loader

6. Remove the bolts from the starter mounting flange
[A]. A
7. Remove the starter from the engine.
6–9.3 Repairing The Starter

Use [B] to disassemble and assemble the starter.
NOTE: DO NOT use solvent to clean the drive

assembly because the solvent will remove
the lubricant and the drive will slip.
B–05957
Use the checking procedure on Page 6–14 to check the
starter parts.

B 1
7
2 8
9
543 & 543B 3
CURRENT MODELS 4
5
11
12 6 10
1. Bolt
2. Frame 13
3. Brush
4. Holder
5. Field Housing
6. Field Coils
7. Solenoid
8. Spring 16
9. Plunger 1
10. Shift Lever 14
11. Gasket
12. Insulator
13. Armature
14. Drive 15
15. Snap Ring
16. Housing
B–01192

540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–ElectricalSectionPages12a–12b
540, 543 Loader

1. Disconnect the connector link between the solenoid
and the starter. A
Early Models
2. Remove the solenoid bolts (Item 1) [A] that fasten
the solenoid to the drive end of the starter.
7
8
3. Remove the solenoid (Item 2) [A].
2 9
4. Remove the bolt (Item 3) [A] and remove the shift
fork (Item 4) [A].
5. Remove the bolts (Item 5) [A] from the end cap 3 14 5

(Item 6) [A].
13
6. Remove the bolts (Item 7) [A] from the armature 12 10 6
(Item 8) [A] shaft at the commutator end. 411
15
7. Remove the armature, complete with the internal
thrust washer (Item 9) [A] and the drive assembly
(Item 10) [A] through the drive end of the starter 1. Bolts 9. Thrust Washer
frame. 2. Solenoid 10. Drive
3. Bolt 11. Thrust Washer
8. Remove the thrust washer (Item 11) [A] from the 4. Fork 12. Stop Ring
commutator end of the armature shaft. 5. Bolts 13. Thrust Collar
6. Cover 14. Brushes
9. Remove the drive stop ring (Item 12) [A], thrust 7. Thrust Washers 15. Bushing

collar (Item 13) [A] and slide the drive assembly off 8. Armature
the armature shaft.
10. Use a brush and air pressure to clean the drive, field
coils, armature, front plate and rear housing.
C–02199
NOTE: DO NOT use solvent to clean the drive
assembly because the solvent will remove
the lubricant and the drive will slip.
11. Inspect the armature for broken or burned insulation

and loose connections at the commutator.
12. Check the armature for opens and grounded circuits

(Fig. 6–43 and 6–44).

13. Check the armature shaft and bearings for damage and wear. If the
commutator is rough, cut it in a lathe to make it smooth.
14. Check the brush holders for broken springs and for broken insulation.
15. Check the spring tension for the brushes.
16. Inspect the field coils for burns or broken insulation and electrical continuity
(Fig. 6–45).
17. Check the starter drive gear for tooth wear. The starter drive gear must
engage more than 1/2 the depth of the ring gear teeth on the flywheel.
A–01995
18. Put a small amount of grease on the shaft of the armature (Fig. 6–42, Item
8). Install the drive assembly (Item 10) and install the thrust collar (Item 13) Fig. 6–43 Checking Armature
and the stop ring (Item 12).
19. Install the thrust washer (Fig. 6–42, Item 11) on the shaft of the armature.
20. Install the armature into the starter housing.
21. Install the brushes in the end plate (Fig. 6–42, Item 14) and install the end
plate on the starter housing.
22. Put a small amount of grease in the bushing (Fig. 6–42, Item 15) and install
the drive housing end.

23. Install the bolts (Fig. 6–42, Item 5) and tighten. Check the end play of the
starter. If there is too much end play or not enough, add or remove shims
(Item 7) at the drive end of the armature.
A–01994
24. Install the shift fork (Fig. 6–42, Item 4) and the pivot bolt (Item 3) and tighten. Fig. 6–44 Checking Armature
25. Install the solenoid (Fig. 6–42, Item 2). Install the bolts (Item 1) and tighten.
26. Connect the link between the solenoid and starter.
6–9.4 Installing The Starter
1. Install the starter into the flywheel housing.
2. Install the starter mounting bolts and tighten to 25–28 ft.–lbs. (34–38 Nm)
torque.
3. Install the starter mounting bracket and tighten the bolts.
4. Connect the wires at the starter solenoid.
5. Install the battery in the loader and connect the battery cables. Connect the
negative cable last.
B–02122
Fig. 6–45 Checking Field Coils
540, 543 Loader

ENGINE SERVICE
Paragraph Page
Number Number
ENGINE SERVICE (KOHLER – 540) . . . . . . . . . . . . . . . . . . 7A–1 7A–1
ENGINE SERVICE (KUBOTA – 543) . . . . . . . . . . . . . . . . . . . 7B–1 7B–1

ENGINE
SERVICE
KOHLER (540)

necessary safety precautions. KUBOTA (543)
death.
540, 543 Loader

203 of 322 –7A––3– Service Manual
540, 543 Loader

ENGINE SERVICE (540)
Paragraph Page
Number Number
CARBURETOR & FUEL SHUT OFF SOLENOID . . . . . . . . 7A–3 7A–6
CHECKS & ADJUSTMENTS FOR THE ENGINE . . . . . . . . 7A–2 7A–3
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–10 7A–15

ENGINE & HEAT SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–5 7A–8
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–12 7A–16

GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–4 7A–7
INTAKE & EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 7A–11 7A–16
OIL PUMP & RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 7A–8 7A–12

PISTONS, ROD AND CRANKSHAFT . . . . . . . . . . . . . . . . . . 7A–9 7A–14
RECONDITIONING THE VALVES . . . . . . . . . . . . . . . . . . . . . 7A–6 7A–11

TIMING COVER, TIMING GEARS & CAMSHAFT . . . . . . . 7A–7 7A–12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–1 7A–1
KOHLER (540)

death.
540, 543 Loader

540, 543 Loader

206 of 322 –7A–0– Service Manual
ENGINE SERVICE – 540 LOADER (KOHLER)
7A–1 TROUBLESHOOTING
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start. 5, 6, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 19, 27, 28, 29, 30
Difficult to start. 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 21, 26, 27, 28, 29, 30
No power from the engine. 7, 8, 9, 10, 11, 14, 16, 17, 18, 19, 20, 21, 22, 23, 24, 27, 28, 29, 30
Engine is mis–firing. 7, 8, 9, 10, 14, 16, 17, 22, 23, 25, 26, 27, 28, 29, 30
Too much fuel consumption. 7, 11, 14, 17, 20, 21, 22, 24, 25, 26, 27, 28, 29, 30

Black exhaust. 7, 11, 14, 16, 17, 19, 21, 22, 24, 25, 26, 28, 29, 30
Low oil pressure. 4, 32, 33, 34, 35, 36, 38, 39, 40, 46
Engine knocking. 9, 16, 23, 25, 26, 28, 30, 32, 41, 47
Engine running rough. 7, 8, 9, 10, 11, 14, 15, 17, 18, 20, 23, 25, 26, 27, 30, 41, 47
Vibration. 14, 15, 17, 20, 22, 23, 26, 27, 30, 41, 43
High oil pressure. 4, 34, 37
Overheating. 11, 16, 21, 41, 42
Too much crankcase pressure. 22, 28, 30, 31, 41, 44
Poor compression. 16, 22, 25, 26, 28, 29, 30, 31
Start and stop. 10, 11, 12
540, 543 Loader

7A–1 TROUBLESHOOTING (Cont’d)

1. Battery capacity low. 25. Incorrect valve tappet adjustment.
2. Bad electrical connection. 26. Sticking valves.
3. Faulty starter motor. 27. Spark plug gap not correct.
4. Incorrect grade of oil. 28. Worn cylinder bores.
5. Low cranking speed. 29. Worn valves and seats.
6. Fuel tank empty. 30. Broken, worn or sticking piston rings.
7. Ignition system has damage. 31. Worn valve stems or guides.
8. Plugged fuel line. 32. Worn or damaged bearings.
9. Faulty fuel lift pump. 33. Not enough oil in the oil pan.
10. Plugged fuel filter. 34. Gauge is not correct.
11. Restriction in the air cleaner. 35. Oil pump is worn.
12. Wrong starting procedure. 36. Pressure relief valve is open.
13. Choke not completely closed. 37. Pressure relief is sticking closed.
14. Choke not completely opened. 38. Broken relief valve spring.

15. Carburetor is dirty or has a defect. 39. Faulty suction pipe.
16. Incorrect valve timing. 40. Plugged oil filter.
17. Poor compression. 41. Piston seizure.
18. Plugged fuel tank vent. 42. Damaged fan.
19. Dirt or water in the fuel. 43. Faulty engine mounting.
20. Sticking or restricted throttle. 44. Plugged breather pipe.
21. Exhaust pipe restriction. 45. Valve stem seals damaged.
22. Cylinder head gasket leaking. 46. Plugged oil pump pipe strainer.
23. Overheating. 47. Broken valve spring.
24. Governor adjustment not correct.
540, 543 Loader

7A–2 CHECKS AND ADJUSTMENTS FOR THE ENGINE
Pressure
7A–2.1 Engine Oil Pressure Gauge
When the engine is operating at normal temperature, with the correct weight oil
and at idle speed, the oil pressure must be within 40–50 PSI (276–345 kPa). If the
oil pressure is higher than specified, it will not cause damage, but it could indicate
that it is operating with the oil weight too thick. If the oil pressure drops suddenly,
this could indicate that the oil pump is faulty or the check valve is not working
correctly and has debris in it.
If the oil pump is faulty, do not attempt to disassemble and repair the pump.
Replace the oil pump with a new pump. There is an external oil pressure
adjustment available.
B–02909
Check the engine oil pressure using the following procedure: Fig. 7A–1 Checking Oil Pressure


2. Remove the oil pressure sender from the engine and install a pressure
gauge (Fig. 7A–1).
3. Start the engine and run it until
it is at operating temperature.
Acorn Nut* Self Locking Nut
4. Check the oil pressure at full Lock Nut
engine RPM. The pressure
must be 40–50 PSI (276–345
kPa).
5. Make the adjustment of the oil

pressure by loosening the jam
nut under the No. 1 cylinder Adjusting
(next to the flywheel) and turn Bolt
the adjustment bolt in or out to
get the correct oil pressure (Fig. *Early Models Have Acorn Nut PI–01908
7A–2).
Fig. 7A–2 Oil Pressure Adjustment
7A–2.2 Valve Clearance

Valve Tappet Clearance
Make the valve adjustment with the
engine stopped and cold.
Put the correct size feeler gauge
between the tappet and the valve
stem and turn the adjustment bolt in
or out to get the correct clearance.
The correct clearance for the intake
is 0.008–0.010 inch (0,203–0,254
mm) and the exhaust is 0.017–0.020
inch (0,432–0,508 mm) (cold) (Fig.
7A–3). PI–01911
Fig. 7A–3 Valve Clearance Adjustment
540, 543 Loader

Use the following procedure to set the valve clearance:
1. Remove the covers from the valve chambers.
A 1 4
2. Turn the crankshaft until there is maximum

clearance between the valve stem and tappet. 2
3. Check the clearance with a feeler gauge (Fig.
7A–3).
4. If the clearance is wrong, turn the bolt at the end of
the tappet until the clearance is correct.
3
7A–2.3 Compression
Speed Control
1. Make sure the engine is at operating temperature. Bracket
2. Remove both spark plugs. B–02282
3. Open the throttle and choke fully.
4. Disconnect the high voltage wire from the coil. B
5. Install the compression gauge in the cylinder to be
checked.
6. Turn the engine several times with the starter.
Check the gauge. The compression must be
100–120 PSI (689–827 kPa). 1
7A–2.4 Throttle And Governor Linkage

Stop the engine. Turn main fuel and idle fuel needles
adjusting screws in until they bottom. DO NOT force
screws or damage will result.
C–02338
C 2
Lift the loader and put jackstands under the

loader frame so there is no danger of the loader
1
For preliminary adjustment, turn the main relief needle

three turns counterclockwise and the idle fuel needle
1–1/4 turn counterclockwise. 3
1. Disconnect the throttle linkage (Item 1) [A] between
the carburetor and the governor arm (Item 2) [A]. PI–01905
2. Hold the throttle on the carburetor fully open. Put the
governor arm against its stop. Adjust the length of
the throttle linkage (Item 1) [A] so it will fit.
3. Push the throttle control fully forward. The speed
stop bolt (Item 3) [A] must be against the stop. If not,
make the adjustment at the stop bolts at the throttle
lever (Item 1) [B].
4. Run the engine at full throttle. Put a load on the
engine (engage the auxiliary or tilt the Bob–Tach all
the way back). Turn the main fuel adjustment (Item
3) [C] in or out to get a smooth engine operation.
5. Start the engine and run it at idle RPM until normal
operating temperatures are reached. Turn the idler
adjustment (Item 1) [C] to get the fastest idle RPM.
Then make an adjustment to the idle fuel
adjustment (Item 2) [C] for correct low RPM.
6. Disengage the load. Check the high–idle RPM. Turn the speed RPM stop
bolt to get the correct RPM.
7. Engage and release the load at full engine RPM. If the governor action for
the engine RPM changes is not smooth, connect the governor spring (Fig.
7A–4, Item 4) to a lower hole on the governor arm. If the engine RPM
becomes slower, move the spring to a higher hole in the governor arm.
8. If the location of the spring was changed, check the high–idle RPM again.
7A–2.6 Ignition System
B–03385
Fig. 7A–7 Adjusting The Points

1

2. Remove the cover from the points at the governor.
3. Remove the old points.

B–02910
4. Install the new points. Turn the engine until maximum point gap is reached. Fig. 7A–8 Timing The Engine
5. Adjust the point gap to 0.020 inch (0,51 mm) (Fig. 7A–7).
6. Remove the cover for the timing hole (Fig. 7A–8, Item 1). Turn the flywheel
until the SP mark is in the timing hole. Put a chalk mark on the SP mark.
7. Start the engine and run it at 1200 RPM.
8. If the timing mark is not correct, loosen the two governor bolts and move the
governor until the SP mark shows in the timing hole.
9. Stop the engine.
10. Check the adjustment of the idle RPM.
7A–2.7 Spark Plugs

Every 100 hours of loader operation, remove the spark plugs, check the condition
and set the gap. Good operating conditions are indicated if the spark plugs have
a light coat of gray or tan deposit. A dead white, blistered coating could indicate
overheating. A black (carbon) coating may indicate an over–rich fuel mixture
caused by clogged air cleaner or the carburetor adjustment is not correct. Replace
the spark plugs as needed.
540, 543 Loader

7A–3 CARBURETOR & FUEL
SHUT–OFF SOLENOID Idle Fuel
Needle Main Fuel
7A–3.1 Removing The Carburetor Needle
1. Stop the engine. Open the rear
door.
2. Disconnect the air cleaner Carburetor
hose. Body
3. Disconnect the fuel line.
4. Disconnect the linkage from the

carburetor.
Fuel Inlet
5. Remove the bolts and nuts Needle And Seat
which hold the carburetor to the Bowl
manifold. Gasket
NOTE: To install the carburetor, Baffle

use the above procedure Pin
in reverse. Make sure to
check adjustment of the
linkage for the governor Float
(See Paragraph 7A–2.4).
Always use new gaskets.

Fuel
7A–3.2 Disassembly And Bowl
Inspection Of The Carburetor (Fig.
7A–9)
PI–01912
1. Remove both mixture screws
and springs. Remove the fuel Fig. 7A–9 Carburetor Assembly
shut–off solenoid.
2. Remove the plug from the float bowl. Remove the bowl from the carburetor
body.
3. Remove the float pin, float and needle.
4. Remove the seat from the carburetor body.
5. Clean all parts. Do not remove the throttle and choke plates unless they are
damaged.
6. Check the float for bends or damage.
7. Check the end of the mixture needles for damage.
7A–3.3 Assembly Of The Carburetor (Fig. 7A–9)
NOTE: Use new gaskets and float valve and seat when assembling the
carburetor.
1. Install the new float valve seat in the carburetor.
2. Put a new bowl gasket and baffle in position.

3. Install the needle on the float. Install the float on the carburetor body.
4. Turn the carburetor so the bottom is up. The float must be parallel to the
gasket surface of the carburetor body. If not, bend the tab on the float to
adjust the float level.
5. Install the bowl. Install the fuel bowl plug and tighten.
6. Install the mixture needles in the carburetor.
540, 543 Loader

7A–3.4 Fuel Shut–off Solenoid
The loader is equipped with a fuel shut–off solenoid [A]. The shut–off solenoid
A
shuts the fuel off when the ignition switch is turned to the OFF position.
NOTE: There is also an electrically operated shut–off located in the
carburetor fuel inlet.
7A–3.5 Non–Metallic Bodied Fuel Pumps
As a product improvement, non–metallic bodied fuel pumps are being installed on
many Kohler Engines instead of the all metal pumps. The thermoplastic body
effectively insulates and prevents fuel from vaporizing inside the pump.
The non–metallic bodied pumps are interchangeable with the metal pumps and
are available in kit form which includes a new mounting gasket and two flat
washers. The following kits are offered.
B–05193
Kit Number Engine Application Feature
41 559 01 K141 thru K181 With Priming Lever
41 559 02 K141 thru K181 Without Priming Lever
47 559 01 K241 thru K361 With Priming Lever Apply Gasoline
47 559 02 K241 thru K341 Without Priming Lever B Resistant Thread Sealant
47 559 04 K241 thru K361 Without Priming Lever* Before Installing Fittings
48 559 01 K482 thru K582 Without Priming Lever Gasket
52 339 01 KT17–KT19–KT21 Without Priming Lever
* Same as 47 559 02 pumps except head reversed to outlet to the right. All others
have outlet to the left.
Some important points regarding the non–metallic bodied fuel pumps are as

follows:
1. Apply a small amount of gasoline resistant thread sealant to fittings before
installing. Turn fittings into pumps 6 full turns and continue turning in the
same direction until the desired position is reached. Flange
2. Use only the gasket provided in the kit. If a thick insulating gasket was used Flat Washer
with the metal pump–discard it.
3. The lock washers and mounting screws from the metal pump can be reused.
Make sure the flat washers provided in the kit are installed next to the flange
to prevent the lock washers from the damaging flange. Torque the mounting C
screws to 40–45 in.–lbs.
7A–4 GOVERNOR
7A–4.1 Removing The Governor
2. Disconnect the linkage from the governor.
3. Disconnect the hose from the governor.
4. Remove the engine shrouding from the right cylinder to reach the lower
governor bolt.
5. Remove the governor bolts. B–02883
6. Remove the crankcase breather.

7. Remove the governor from the engine.
NOTE: The governor must be replaced as an assembly and can not be
D
repaired. Remove the ignition point cover, ignition points [C], push
rod and linkage from the governor. Install these parts on the new
governor.
7A–4.2 Installing The Governor
1. Remove the plug from the top of the governor adapter and ignition timing
hole [D].
2. Turn the flywheel so the D.C. mark can be seen.
3. Install the governor so the bevel on the gear is in alignment with the hole in
the governor adapter [D].
4. Check the adjustment of the timing governor linkage. B–02293

7A–5 ENGINE AND HEAT SHIELD
7A–5.1 Removing The Engine
WARNING
jackstands under the loader
frame so there is no danger of
the loader falling and causing B–06010 B–06011
personal injury.
Fig. 7A–13 Muffler Clamp Fig. 7A–14 Muffler Bracket Clamp
1. Remove the rear door from the

loader (See Paragraph 5–4.1,
Page 5–9).
2. Remove the ground cable from

the battery and remove the
battery from the loader (See
3. Remove the muffler clamp (Fig.

7A–13).
4. Remove the U–clamp at the

muffler bracket (Fig. 7A–14). B–06012 B–06013
Fig. 7A–15 Engine Muffler Fig. 7A–16 Fuel Shut–Off Valve
5. Remove the muffler from the
engine (Fig. 7A–15).
6. Shut off the fuel at the fuel tank

(Fig. 7A–16).
7. Disconnect the fuel line hose at

the fuel shut–off solenoid (Fig.
7A–17).
8. Move the clamp on the choke

cable away from the heat shield
(Fig. 7A–18).
9. Disconnect the choke cable at

the carburetor (Fig. 7A–19). B–06014 B–06015
Fig. 7A–17 Fuel Hose Clamp Fig. 7A–18 Choke Cable Clamp
10. Disconnect the throttle linkage
at the pivot shaft, at the heat
shield.
11. Remove the air cleaner hose at

the carburetor (Fig. 7A–20).
A–02779 B–06016
Fig. 7A–19 Disconnect The Choke Cable Fig. 7A–20 Air Cleaner Hose
540, 543 Loader

12. Remove the nuts and bolts at
the starter solenoid (Fig.
7A–21).
13. Disconnect the wire for the fuel

shut–off solenoid (Fig. 7A–22).
14. Disconnect the wires at the

rectifier/regulator (Fig. 7A–23,
Item 1).
15. Remove the bolts and nuts (Fig.

7A–23, Item 2) from the bracket
which mounts the air cleaner B–05199 B–06017
and the rectifier/regulator, Fig. 7A–21 Starter Solenoid Fig. 7A–22 Fuel Shut–Off Wire
remove the assembly from the
loader.
17. Remove the clamp at the engine wiring harness (Fig. 7A–24).
18. Remove the engine mounting bolts (both sides) (Fig. 7A–25).
19. Remove the bolts (both sides) which mount the hydrostatic pumps to the
engine.

20. Install the engine removal stand (Fig. 7A–26, Item 1).
21. Using pry bars, lift the rear of the engine and put it on the stand.
22. Slide the engine out of the rear of the loader on the stand (Fig. 7A–26).
7A–5.2 Installing The Engine
1. Slide the engine into the loader

until the crankshaft is in contact
with the drive coupler. Make
alignment of the drive coupler to
the splines on the engine.
B–06018
2. Install the engine mounting Fig. 7A–23 Air Cleaner Bracket
bolts and tighten (Fig. 7A–25).
3. Install the bolts at the

hydrostatic pumps and tighten.
B–06019
4. Install the engine wire harness Fig. 7A–24 Engine Wire Harness
clamp (Fig. 7A–24).
B–05200 B–06020
Fig. 7A–25 Engine Mount Bolts Fig. 7A–26 Removing The Engine
540, 543 Loader

5. Install the air cleaner and
rectifier/regulator assembly
into the loader.
6. Connect the wires to the

rectifier/regulator (Fig. 7A–23,
Item 1).
7. Connect the wire for the fuel

shut–off solenoid (Fig. 7A–22).
8. Install the starter solenoid (Fig.

7A–23).
B–06021
9. Connect the throttle linkage and Fig. 7A–27 Throttle Pivot Linkage
choke cable.
10. Connect the fuel line hose (Fig. 7A–17). Open the fuel shut–off valve (Fig.
7A–16).
11. Install the air cleaner hose at the intake manifold.
12. Install the muffler, install the clamp at the bracket and the clamp at the
exhaust pipe.
13. Install the battery (See Paragraph 6–3.3, Page 6–4).

14. Install the rear door (See Paragraph 5–4.1, Page 5–10).
B–06022
Fig. 7A–28 Heat Shield Bolts
7A–5.3 Removing The Heat Shield
1. Remove the engine from the loader (See Paragraph 7A–5.1).
2. Disconnect the throttle linkage at the pivot lever (Fig. 7A–27).
3. Remove the two bolts at the rear of the engine (Fig. 7A–28).
4. Remove the bolts at the bottom of the heat shield (both sides) (Fig. 7A–29).
5. Remove the heat shield from the engine.
B–06023
Fig. 7A–29 Heat Shield Bolts
7A–5.4 Installing The Heat Shield
1. Install the heat shield on the engine, install the bolts at the bottom of the heat
shield (Fig. 7A–29) and tighten.
2. Install the bolts at the rear of the engine and tighten (Fig. 7A–28).
3. Connect the throttle linkage (Fig. 7A–27).
4. Install the engine in the loader (See Paragraph 7A–5.2).

7A–6 RECONDITIONING THE
VALVES
7A–6.1 Repair Of The Valves And
Guides
1. Remove the engine from the

loader (See Paragraph
7A–5.1).
2. Remove the shrouding,

cylinder heads and the valve
chamber covers.
PI–01906
3. Turn the crankshaft and check Fig. 7A–30 Removing Valve Springs And Locks
the amount of valve lift. If not
enough the cam is worn and
needs to be replaced (See
Section 8 for the
Specifications).
4. Use a valve compressor to remove the valve springs (Fig. 7A–30).
NOTE: There are valve rotators under the exhaust valve springs. The
exhaust valve springs are shorter. The close coils of the springs go

toward the cylinder head.
5. Check the clearance between the valves and guides. If over maximum
remove the guides and install new guides.
6. Use a reamer, of the correct size, in the new guides to make them fit the valve
stems.
7. Check the exhaust valve seat for wear, distortion or cracks. Use a valve seat
tool to remove the old seats, if needed.
NOTE: The exhaust valve seat is the only seat that can be replaced.
8. Grind the valves and seats. Use a grinding compound to check that the
valves are fitted correctly and the seat is at the correct width.
Carefully inspect the valve mechanism parts. Check valves and valve seat areas
or inserts for a condition of deep pitting, cracks or distortion. Check the clearance
of the valve stems in the guides.
If the valve seat insert is badly worn, warped, damaged or if seating surface is
badly pitted, the insert must be replaced. The inserts are a tight press fit in the
cylinder head. A valve seat removal tool is used for this job. Since the insert
removal causes loss of metal in the insert bore area in the head, use only service
replacement inserts which have a knurled outer edge to provide proper fit in the
cylinder head. Make sure the service inserts are properly started and pressed into
the bore to prevent the insert from seating at an angle.
540, 543 Loader

7A–7 TIMING COVER, TIMING GEARS AND CAMSHAFT
7A–7.1 Timing Cover
1. Remove the air housing for the flywheel. Gear Cover

Alignment
2. Remove the bolts which hold the timing cover in position and slide it off the
crankshaft.
3. When installing the timing cover, make a note of the two special bolts (Fig.
7A–31). Install and tighten these two bolts first.
7A–7.2 Timing Gears

Second
While the timing cover is off the engine, the gears can be removed. The camshaft Hole Up
gear is removed by putting a block of wood between the gear teeth and removing
the nut from the camshaft. Then remove the gear from the camshaft. Remove the
snap ring from the end of the crankshaft and remove the crankshaft gear. Third
Hole Up PI–01906
Fig. 7A–31 Timing Cover
NOTE: If the oil pump gear needs

replacement, you must
replace the oil pump
assembly.

Make sure the timing marks are in
correct alignment when installing the
gears (Fig. 7A–32).
7A–7.3 Camshaft And Tappets

The gear cover must be removed to
remove the camshaft gear. Remove
all of the bolts which hold the gear
cover plate in place. Remove the
cylinder heads and valves. Turn the
camshaft to push the tappets out of
the way and remove the camshaft PI–01909
from the engine. Fig. 7A–32 Alignment Of The Timing Marks
NOTE: If the camshaft is replaced, the tappets must also be replaced. To

replace the tappets, you must remove the oil pan.
7A–8 OIL PUMP AND RELIEF VALVE

7A–8.1 Relief Valve
The relief valve for the oil pressure is under the No. 1 cylinder (Fig. 7A–33, Item
1). The oil pressure is adjusted by loosening the jam nut and turning the screw in
or out (See Paragraph 7A–2.1).
1
B–02861
Fig. 7A–33 Relief Valve
540, 543 Loader

7A–8.2 Oil Pump
If the oil pump has a defect, you must replace the oil pump as an assembly.
To remove the oil pump, remove the oil pan and remove the oil pump screen. Then
remove the flywheel and gear cover. Remove the two bolts which hold the oil pump
to the engine block and lift it out of the engine (Fig. 7A–34).
7A–8.3 Adjusting Gear Clearance For The Oil Pump

When installing the oil pump on the engine, it is important to adjust the clearance
between the oil pump gear and the crankshaft gear. The clearance between the
gears is 0.005–0.009 inch (0,127–0,228 mm). A feeler gauge or a dial indicator
can be used. B–02856
Fig. 7A–34 Oil Pump
To set the clearance with a feeler gauge:
1. After the oil pump is installed,

do not tighten the bolts.
2. Use a 0.007 inch (0,177 mm)

feeler gauge and adjust the
clearance between the oil pump
and crankshaft gear (Fig.
7A–35). Tighten the mounting
bolts.

3. Check the clearance at two
other locations (120° from each
other) to make sure the
A–02643
clearance is correct.
Fig. 7A–35 Checking Gear Clearance
4. If one or more locations do not
have the same clearance,
loosen the bolts and adjust the
clearance until all three
locations have the same
clearance.
To set the clearance with a dial

indicator:
1. After the oil pump is installed,

do not tighten the mounting
bolts.
2. Mount a dial indicator on the

engine (Fig. 7A–36). Make sure
the dial indicator arm is tight
against one of the gear teeth.
Zero the dial indicator.
A–02642
Fig. 7A–36 Checking Gear Clearance
540, 543 Loader

3. Adjust the clearance by moving the oil pump backward and forward until the
clearance is between 0.005–0.009 inch (0,127–0,228 mm). Tighten the
mounting bolts.
4. Check the clearance at two other locations (120° from each other) to make
sure the clearance is correct.
5. If one or more locations do not have the same clearance, loosen the bolts
and adjust the clearance until all three locations have the same clearance.
7A–9 PISTONS, RODS AND CRANKSHAFT

7A–9.1 Removing Pistons, Rods And Crankshaft
1. Remove the engine flywheel, oil pan and oil pump.
2. Put a mark on the rods and caps. The caps, rods and pistons must be C–02339
installed in the same cylinder bore that they were removed from.
Fig. 7A–37 Removing Piston
NOTE: The notch on the cap and the notch on the rod must be together.
3. Remove the rod bolts and caps and remove the pistons from the engine (Fig.
7A–37). Install caps on connecting rods.

4. Remove the adapter and the bearing plate and the snap ring from the end
of the crankshaft. Remove the bearing plate, with the bearing, from the
engine.
5. Remove the crankshaft from the engine. Be careful to prevent damage to the
bearing in the engine block.
6. Check the following items:

(a) Crankshaft: Keyway, journal diameters, out–of–round conditions.
(b) Rods: Condition of the bearing surfaces.
(c) Pistons: Scratch marks, ring groove, clearance, cracks or damage.
(d) Cylinder Block: Condition of the bearings, cylinder walls.
A–02780
Fig. 7A–38 Installing Bearing
7A–9.2 Crankshaft Bearing And End Play

The engine uses a ball bearing which is located in the closure plate and on the
crankshaft. It is not necessary to separate the crankshaft from the closure plate
if the bearing turns easily on the shaft or there is no noise from the bearing.
To replace the bearing, remove the inner retaining ring then press the crankshaft
out of the closure plate (Fig. 7A–38). The bearing will stay on the shaft and can
be pressed off after the two snap rings are removed (Fig. 7A–39). Clean the
bearing in clean solvent and allow to dry. Put engine oil on the bearing and check
the condition. Replace as needed.
A–02781
Fig. 7A–39 Installing Closure Plate
540, 543 Loader

Use a cylinder hone to hone the correct surface on the
cylinder walls [A]. Check the clearance between the A
piston and cylinder wall. If it is over maximum, use an
oversize piston.
If the new main bearing inserts are installed in the block,
push the bearing even with the outside surface of the
block. Make sure the oil holes in the bearings are in
alignment with the holes in the engine block. Cross Hatch
Pattern After
Reboring
PI–01907
Check the ring gap in the cylinder bore [B].

B

PI–01904
Install the rings on the pistons [C].

Install the piston and rod assembly and tighten the rod
C Bevel Up
bolts to 200 in.–lbs. (23 Nm) torque.
Bevel Down
B–02284
7A–10 CYLINDER HEAD

D
Use a new gasket. Put the cylinder in position and install
the bolts. Make sure the washers are used. Tighten the
bolts to 35 ft.–lbs. (48 Nm) torque in the correct sequence
[D].
A–02678

7A–11 INTAKE AND EXHAUST MANIFOLD
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–EngineServiceSection7APages1–16
Put a heavy flat washer or spacers on the manifold where the bolts are used to
fasten the manifold and side panels to the engine block. Install the intake and
exhaust manifold, tighten the bolts to 25 ft.–lbs. (34 Nm) torque.
7A–12 FLYWHEEL
It is not necessary to remove the engine from the loader to remove the flywheel.
Remove the four bolts and use a puller to remove the flywheel from the engine
crankshaft.
Check the flywheel (Fig. 7A–45) for broken fins, cracks or keyway damage. Do B–02981
not try to replace the ring gear on the flywheel. You must replace the flywheel and Fig. 7A–45 Engine Flywheel
ring gear as an assembly.
540, 543 Loader

ENGINE SERVICE (543 & 543B)
Paragraph Page
Number Number
ASSEMBLY OF THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 7B–6 7B–29
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–4 7B–16
ENGINE AND ATTACHING PARTS . . . . . . . . . . . . . . . . . . . . 7B–3 7B–8

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–2 7B–3
REPAIRING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–5 7B–21

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–1 7B–1

DO NOT service the Bobcat loader KUBOTA (543)
death.

223 of 322 –7B––1– Service Manual
540, 543 Loader

224 of 322 –7B–0– Service Manual
7B ENGINE SERVICE – 543 LOADER (KUBOTA)
7B–1 Troubleshooting
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start. 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 22, 30, 31, 32
Difficult to start. 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 23, 28, 30, 31, 32
No power from the engine. 8, 9, 10, 11, 12, 13, 14, 18, 19, 20, 21, 22, 23, 24, 25, 26, 30, 31, 32
Engine is mis–firing. 8, 9, 10, 11, 12, 13, 14, 16, 18, 19, 20, 24, 25, 27, 28, 30, 31, 32
Too much fuel consumption. 11, 13, 14, 16, 18, 20, 22, 23, 24, 26, 27, 28, 30, 31, 32

Black exhaust. 11, 13, 14, 16, 18, 19, 20, 22, 23, 24, 26, 27, 28, 30, 31, 32
Blue/White Exhaust. 4, 16, 18, 19, 20, 24, 26, 30, 32, 33, 34, 44, 54
Low oil pressure. 4, 35, 36, 37, 38, 39, 41, 42, 43, 56
Engine knocking. 9, 14, 16, 18, 19, 22, 25, 27, 28, 30, 32, 34, 35, 44, 45, 57
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 14, 16, 20, 21, 25, 27, 28, 29, 32, 34, 44, 57
Vibration. 13, 14, 20, 24, 25, 28, 29, 32, 44, 47
High oil pressure. 4, 37, 40
Overheating. 11, 13, 14, 16, 18, 19, 23, 24, 44, 46, 48, 49, 50, 51, 52, 55
Too much crankcase pressure. 24, 30, 32, 33, 44, 53
Poor compression. 11, 19, 24, 27, 28, 30, 31, 32, 33, 45, 57
Start and Stop. 10, 11, 12
540, 543 Loader

7B–1 Troubleshooting (Cont’d)
1. Battery capacity low. 30. Worn cylinder bores.
2. Bad electrical connection. 31. Worn valves and seats.
3. Faulty starter motor. 32. Broken, worn or sticking piston rings.
4. Incorrect grade of oil. 33. Worn valve stems and guides.
5. Low cranking speed. 34. Overly full air cleaner.
6. Fuel tank empty. 35. Worn or damaged bearings.
7. Faulty stop control operation. 36. Not enough oil in the oil pan.
8. Plugged fuel line. 37. Gauge is not correct.
9. Faulty fuel lift pump. 38. Oil pump worn.
10. Plugged fuel filter.

39. Pressure relief valve is open.
11. Restriction in the air cleaner. 40. Pressure relief valve is sticking closed.
12. Air in the fuel system. 41. Broken relief valve spring.
13. Faulty fuel injection pump. 42. Faulty suction pipe.
14. Faulty fuel injectors. 43. Plugged oil filter.
15. Incorrect use of the glow plugs. 44. Piston seizure.
16. Glow plugs not working. 45. Incorrect piston height.
17. Broken fuel injection pump drive. 46. Damaged fan.
18. Incorrect fuel pump timing. 47. Faulty engine mounting.
19. Incorrect valve timing. 48. Faulty thermostat.
20. Poor compression. 49. Restriction in the water jacket.
21. Plugged fuel tank vent. 50. Loose fan belt.
22. Incorrect type or grade of fuel. 51. Plugged radiator.
23. Exhaust pipe restriction. 52. Faulty water pump.
24. Cylinder head gasket leaking. 53. Plugged breather pipe.
25. Overheating. 54. Valve stem seals damaged.
26. Cold running. 55. Coolant level low.
27. Incorrect valve tappet adjustment. 56. Plugged oil pump pipe strainer.
28. Sticking valves. 57. Broken valve spring.
29. Incorrect high pressure tubelines.
540, 543 Loader

7B–2 FUEL SYSTEM
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–EngineServiceSection7BPages1–3
2
7B–2.1 Replacing The Fuel Filter 1
The fuel filter is on the right hand side of the engine in the engine compartment
(Fig. 7B–1). Replace the fuel filter every 500 hours of loader operation.
To replace the fuel filter, use the following procedure:
1. Clean the area around the fuel filter.
2. Shut–off the fuel at the fuel tank.
3. Remove the thumb screw at the bottom of the filter, drain the fuel from the B–05840
filter. Fig. 7B–1 Fuel Filter
4. Remove the filter by removing the small bolt at the top of the filter head while
holding the nut below the filter bowl (Fig. 7B–1, Item 1). Remove the filter
bowl.
5. Check the condition of the seals, replace as needed.
6. Install the filter, bowl, bolt, nut and thumb screw. Tighten the thumb screw
finger tight only.
7. Turn on the fuel shut–off valve. 1

8. Remove the air from the fuel system (See Paragraph 7B–2.2).
9. After the engine is running, check for leaks.

B–05839
Fig. 7B–2 Injection Pump Vent
7B–2.2 To Remove The Air From The Fuel System

After replacement of 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.
To remove the air from the fuel system, use the following procedure:
1. Open the vent (Fig. 7B–1, Item 1) on the fuel injection pump.
2. Operate the hand pump at the fuel filter (Fig. 7B–1, Item 2) until fuel flows
from the vent plug with no air bubbles.
3. Tighten the vent plug (Fig. 7B–1, Item 1). Operate the hand pump until it feels C–02601
solid.
Fig. 7B–3 Engine Stop Control
4. Put the engine stop control (Fig. 7B–3) in the operating position.
5. Start the engine.
6. If the engine still does not run correctly (rough), do steps 1 thru 5 again.

7B–2.3 Fuel Injection Pump
The injection pump has parts that have been machined to a very close
specification and pump operation has a direct effect on the engine performance.
Use special care when working on the injection pump.
Checking The Injection Pump

MEL1237 – Adapter Fuel Line
MEL1173–1 – Pressure Gauge
B–05959
Fig. 7B–3a Injection Pump Tubeline
1. To check the initial discharge

pressure, remove a high
pressure tubeline (Fig. 7B–3a)
at the fuel injection pump.
2. Loosen the other end of the

tubeline at the injector, so that
the tubeline can be turned away 2
from the fitting.

3. Connect a pressure gauge to
the long leg of the test tubeline
(Fig. 7B–3b, Items 1 & 2) and 1
tighten. B–08235
Fig. 7B–3b Testing The Injection Pump
4. Connect the short leg of the
tubeline to the fitting at the fuel
injection pump (Fig. 7B–3b,
Item 2).
5. Rotate the engine, with the starter, until pressure begins to rise. Then turn
engine by hand until 2133 PSI (14707 kPa) is reached.
6. Pump must hold 2133 PSI (14707 kPa) for at least 5 seconds.
7. If the time is less than the allowable limit, replace the injection pump.

228 of 322 –7B–3a– Service Manual
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–EngineServiceSection7BPages3a–3b
540, 543 Loader

229 of 322 –7B–3b– Service Manual
If you do not have the correct
equipment and trained personnel,
IMPORTANT adjustment or maintenance must not
be done.
To remove the fuel injection pump, use the following procedure:
1. Clean the injection pump and the area around it with a cleaning solvent or
by steam cleaning.
B–05958
Fig. 7B–4 Injector Nozzle Tubeline
IMPORTANT
Never steam clean or put cold
water on an injection pump
while the engine is running or
while it is hot. If you do it will
cause serious damage to the
injection pump.
2. Remove the fuel injector

tubelines at the fuel injectors
and the injection pump (Fig.
7B–4 & 7B–5).
B–05959 B–05960
3. Disconnect the wire from the
glow plug (Fig. 7B–6). Fig. 7B–5 Injector Pump Tubeline Fig. 7B–6 Glow Plug Wire

intake manifold (Fig. 7B–7).
5. Remove the intake manifold

from the engine (Fig. 7B–8).
B–05962 B–05963
Fig. 7B–7 Intake Manifold Bolts Fig. 7B–8 Intake Manifold
6. Remove the fuel inlet hose (Fig.

7B–9, Item 1) and the fuel 1
return hose (Item 2). 2
7. Remove the engine lift hook
from the engine block (Fig.
7B–10, Item 1). 1
8. Remove the four nuts from the
injection pump (Fig. 7B–10).
9. Put the pin in the control rack in

alignment with the slot in the
engine block. B–05964 B–05965
Fig. 7B–9 Inlet Fuel Hose Fig. 7B–10 Injection Pump Nuts
540, 543 Loader

10. Remove the injection pump [A].
A
NOTE: Make sure the same number of shims are
installed under the injection pump because
the shims are for the engine timing.
Installation
When the injection pump is installed, make sure the pin
on the control rack is correctly installed in the fork lever
number 1 slot (Item 1) [A]. If the pin is not correctly
installed, the engine will run over maximum speed and
serious damage can result.
1
To install the injection pump, use the following procedure: B–05966
NOTE: Make sure the correct number of shims are

installed. B
1. Install the injection pump with the shims between
the pump housing and the engine block [A].
2
2. Tighten the four nuts to 17–20 ft.–lbs. (23–27 Nm)
torque (Fig. 7B–10). 1

3. Install the fuel inlet hose (Fig. 7B–9, Item 1) and
return hose (Item 2).
4. Install the intake manifold (Fig. 7B–8) and tighten

the bolts (Fig. 7B–7).
B–10007
5. Install the engine lift hook.
6. Connect the wire to the glow plugs (Fig. 7B–6).
7. Check the diverter valve nut (Item 2) for correct

torque of 29–36 ft.–lbs. (39–49 Nm) [B].
8. Install the high pressure tubelines at the injection

pump and the injector nozzles (7B–4 & 7B–5) and
tighten.
9. Remove the air from the fuel system (See

Paragraph 7B–2.2)
7B–2.4 Timing The Fuel Injection Pump

Timing of the fuel injection pump is done by changing the
number of shims between the injection pump and the
engine block (Item 1) [B]. Each shim will change the
timing 1.5 degrees. The timing of the fuel injection pump
will be later when a shim is added, and earlier when a shim
is removed.
To time the fuel injection pump, use the following
procedure:
1. Remove the Number 1 cylinder high pressure

tubeline at the injection pump.

2. Install a short pipe to the outlet
of the number 1 outlet of the
injection pump. Point the pipe
up (vertical).
3. With a fuel supply to the

injection pump, rotate the
engine in a clockwise direction
(viewed at the rear of the
loader). Fuel must flow from the
pipe as the mark on the
crankshaft sheave and the
pointer are in alignment (Fig.
7B–13). The correct timing for B–05968 B–05967
the engine is 23 to 25 degrees
B.T.D.C. Fig. 7B–13 Engine Timing Marks
4. Add or subtract shims as needed to adjust the delivery time of the fuel
injection pump. Each shim will change the timing 1.5 degrees.
7B–2.5 Fuel Injector Nozzles
Diesel fuel under pressure can have

enough force to penetrate the skin.

Make sure all the connections are
tight. Check the lines, pipes and
WARNING hoses for damage before you
disconnect any line. Use a piece of
cardboard or wood to find a small B–05958
hole. Get immediate medical
Fig. 7B–14 Injector Nozzle Tubelines
attention if you get an injury from
diesel fuel.
These are some engine problems caused by damaged injector nozzles:

(a) The engine is hard to start or will not start.
(b) Engine operation is not smooth.
(c) The engine will not idle correctly.
(d) Bad engine performance.
B–05969
(e) The engine exhaust smoke is black, white or blue. Fig. 7B–15 Injector Banjo Fitting
Remove the injector nozzles from the engine and test the injectors only after
engine performance shows that there may be damage.
Removal
To remove the injector nozzles, use the following procedure:
1. Remove the high pressure tubelines from the injectors (Fig. 7B–14).
Remove the valve cover.
2. Remove the fuel return from the banjo fittings.
3. Remove the banjo fitting from the fuel injector (Fig. 7B–15).
B–05970
4. Loosen the fuel injector with a special socket (Fig. 7B–16). Fig. 7B–16 Fuel Injector Socket

5. Remove the fuel injector nozzle from the engine (Fig. 7B–17).
DO NOT disassemble or test the

injector nozzles unless you have the
IMPORTANT correct service and testing tools.
B–05971
Fig. 7B–17 Fuel Injector Nozzle
Checking The Fuel Injector
Nozzles
the following procedure: 3
MEL10018 – Injection Nozzle Tester
MEL10019 – Accessory Set
NOTE: You can adjust the release

pressure of the injector

nozzle by adding or
removing spacers (Fig. 2
7B–18, Item 1) from the top
of the nozzle spring (Item 1
2). Each spacer will B–04103
change the release
pressure about 70 PSI (483 Fig. 7B–18 Injector Nozzle Assembly
kPa). The release pressure
must be 1900–2133 PSI
(13721–14707 kPa).
Do not disassemble or test fuel

injector nozzles unless you have
correct service and testing tools.
Keep away from fuel coming from
WARNING the nozzles. Wear safety goggles.
Fuel under pressure can penetrate
skin or eyes. If fuel enters skin or
eyes, get immediate medical
attention.
W–1036
1. Connect the injector nozzle to the tester with the nozzle in a down position
(Fig. 7B–19).
2. Slowly operate the hand lever of the test pump until the injector nozzle valve
opens. The pressure must be 1990–2133 PSI (13721–14707 kPa).
3. If the pressure is not correct, disassemble the injector nozzle and add or
remove spacers (Fig. 7B–18, Item 1).
NOTE: When assembling the injector nozzle, tighten the retainer nut (Fig.
7B–18, Item 3) to 43–58 ft.–lbs. (59–79 Nm) torque. Any higher torque
will cause slow action of the valve.
A–02513
Fig. 7B–19 Testing The Nozzle

4. Check for inside leakage. Operate the hand lever
until the pressure is almost enough to open the A
injection valve. Make a record of the pressure. Spring
Release the hand lever. Check the pressure
decrease for 10 seconds. The nozzle has damage CORRECT WRONG
if the pressure decrease is more 740 PSI (5162 Pressure
kPa)in 10 seconds. Pin Holder
5. Check the spray pattern of the nozzle for the

following conditions [A].
(a) Does not come out the side of the nozzle. Nozzle Body
(b) Does not have drops coming from the nozzle. Needle Valve
(c) Does not have a flow (solid stream) coming from A–02621
the nozzle.
Any of the above conditions show a defect or a dirty

injector nozzle. Clean the nozzle that does not operate
correctly and check again.

Installation
A
Install the injector nozzle in the cylinder head and tighten
to 22–36 ft.–lbs. (29–49 Nm) torque.
Install the banjo fitting on the injector nozzle and tighten.
Connect the return fuel hoses to the banjo fitting.
Install the high pressure tubelines at the injector and
tighten.
Remove the air from the fuel system (See Paragraph
7B–2.2 for the correct procedure).
P–03419
7B–2.6 Glow Plugs
Checking B
Disconnect the flow plug cables and leads.
Touch one probe to the end of the glow plug and the other
probe to the body of the glow plug [A].
The reading must be approximately 1.5 ohms. If the
resistance is zero ohms the glow plug has a short circuit.

If the resistance is infinite the coil of the glow plug is
broken.
Repeat the procedure for each glow plug.
Replace the glow plugs as needed [B].
P–03420
7B–3 ENGINE AND ATTACHING PARTS C

7B–3.1 Removing The Engine
Use the following procedure to remove the engine from 1
the loader:
Open the rear door and clean the area around the engine.
Remove the air cleaner hose (Item 1) [C] from the intake
manifold. 2
Remove the air intake hose (Item 2) [C].
P–03415
Remove the bolts from the clamps on the air cleaner.

Remove the air cleaner assembly from the loader [D]. D
B–05974

7B–3 ENGINE AND ATTACHING PARTS (Cont’d)
A
7B–3.1 Removing The Engine (Cont’d)
Remove the four bolts from the rear grill and remove the
rear grill [A].
Remove the radiator cap.
P–03412
Install a drain hose on the drain valve and remove the

coolant from the engine and the radiator [B]. B

B–05846
Remove the radiator hoses (Item 1) [C] from the radiator.

There are four mounting bolts for the radiator, two in the
C
rear (Item 2) [C] and two in front of the oil cooler.
NOTE: Remove the oil cooler cover (Item 3) [C] to

access the two front radiator mounting bolts.
1 2 1
Disconnect the ground cable from the battery and remove
the battery from the loader (See Section 6, Paragraph
6–3.1 for the correct procedure). 3
P–03417
Remove the nut (Item 1) [D] from the throttle linkage.

D
Remove the bolt (Item 2) [D] from the engine stop cable
and remove the cable from the injection pump [D].
1
B–03418

A
Remove the engine ground cable [A].
B–05977
Disconnect the engine wiring harness connector [B].

B

B–05978
Disconnect the wires from the solenoids [C].

Shutoff the fuel.
C
B–05980
Remove the exhaust pipe from the muffler [D].

D
B–05984

A
Remove the two fuel hoses from the fuel tank [A].
B–05982
Remove the front engine mount bolts (both sides) [B].

B

B–05986
Remove the rear engine mount bolts (both sides) [C].

Install an engine removal stand at the rear of the loader.
C
Use pry bars to lift the rear edge of the engine on the
stand.
B–05987
Slide the engine to the rear and onto the stand [D].
D
B–05988

A
7B–3.2 Installing The Engine
Raise the operator cab (See Paragraph 5–1.1, Page
5–1).
Slide the engine into the loader until the U–joint coupler
makes contact with the hydrostatic pump shaft.
Have a second person align the coupler on the engine
flywheel to the splined shaft of the hydrostatic pump from
the side of the operator area.
Install the engine mounting bolts (front and rear) and
tighten to 65–70 ft.–lbs. (88–95 Nm) torque.
P–03412
Install the oil cooler cover and exhaust pipe.
Connect the stop control cable and the throttle linkage at
the fuel injection pump.
Connect the two fuel line hoses at the fuel tank. Open the
fuel shutoff valve.
Connect the wires to the solenoids and connect the
engine wiring harness.

Connect the engine ground cable.
Install the battery in the loader (See Section 6, Paragraph
6–3.3).
Connect the radiator hoses and tighten the clamps.
Add pre–mix 50/50 water and anti–freeze to the coolant

system (See Section 8 for the correct capacity).
Install the rear grill on the loader and tighten the bolts [A].
Connect the air cleaner hose to the intake manifold and
tighten the clamps.

A
7B–3.3 Engine Muffler
Removal
Remove the exhaust pipe from the muffler [A].
B–05984
Remove the nut (at the starter) for the muffler mounting
bracket [B]. B
Remove the four nuts at the exhaust manifold [C].

Remove the muffler from the exhaust manifold.
Installation
Install the muffler on the exhaust manifold. B–05989
Install the four nuts and tighten [C].

Install the bracket and tighten the nut [B].
C
Install the exhaust pipe [A].
B–05990

A
7B–3.4 Engine Radiator
Removal
Remove the rear grill [A].
P–03412
Remove the coolant from the engine and the radiator,

using a drain hose on the drain valve on the engine [B]. B
NOTE: The radiator cap must be loosened to remove
all the coolant from the system.

B–05846
Remove the radiator hoses (both sides) [C].

C
B–05976
Remove the radiator cover [D]. D
P–03414

A
7B–3.4 Engine Radiator (Cont’d)
Remove the oil cooler cover [A].
B–05985
Remove the blower housing bolts [B].

B

B–05992
Remove the bolts at the front of the oil cooler [C].

C
B–05993
Remove the tubelines from the oil cooler (both sides) [D].
D
B–05994

A
7B–3.4 Engine Radiator (Cont’d)
Remove the hose clamps (Item 1 & 2) [A] from the 1
recovery tank hose.
B–14152
Remove the coolant recovery tank [B]. B

Remove the nuts at the front of the radiator mounting
bracket [C].
Remove the radiator and oil cooler assembly from the
loader [D].
Remove the radiator from the mounting bracket.

Installation
Install the radiator in the mounting bracket and tighten the
bolts.
B–05998
Install the radiator and oil cooler assembly into the loader
[D].
Install the nuts at the front of the radiator mounting
C
bracket and tighten [C].
Install the coolant recovery tank [B].
Install the recovery tank hose and clamps (Item 1 & 2) [A].
Install the oil cooler tubelines (both sides) and tighten
(See Page 7B–14, [D]).
Install the bolts at the front of the oil cooler. (See Page
7B–14, [C]).
Install the blower housing bolts. (See Page 7B–14, [B]).
B–05999
Install the oil cooler cover and the radiator cover (See
Page 7B–14, [A] & Page 7B–13, [D]).
Install the radiator hoses (both sides) and tighten the D
clamps.
Add premix 50/50 water and anti–freeze to the coolant
system (See Section 8 for the correct capacity).
Install the rear grill on the loader.
P–03416

A
7B–3.5 Engine Blower Housing
Removal
Remove the engine from the loader (See Paragraph
7B–3.1).
Remove the radiator and oil cooler assembly (See
Paragraph 7B–3.4).
Remove the bolt from the bottom of the blower housing
[A].
B–06002
Remove the blower housing from the loader [B].

B

B–06003

Installation
1. Install the blower housing in the loader (Fig. 7B–54).
2. Install the bottom bolt in the blower housing and tighten (Fig. 7B–53).
3. Install the radiator and oil cooler assembly (See Paragraph 7B–3.4).
4. Install the engine in the loader (See Paragraph 7B–3.2).
B–06004
7B–3.6 Engine Blower Fan And Flywheel Fig. 7B–55 U–joint Coupler Bolts
Removal
1. Remove the engine from the loader (See Paragraph 7B–3.1).
2. Remove the four bolts from the U–joint coupler (Fig. 7B–55).
3. Remove the four bolts from the blower fan (Fig. 7B–56).
4. Using a chisel and hammer, loosen the bolt locks for the flywheel bolts (Fig.
7B–57).

5. Remove the four bolts from the flywheel (Fig. 7B–58).
6. Remove the flywheel from the engine crankshaft. B–06005

Fig. 7B–56 Blower Fan Bolts
Installation
1. Install the flywheel on the engine crankshaft flange.
2. Install the four bolts and tighten to 40–45 ft.–lbs. (54–61 Nm) torque (Fig.
7B–58).
3. Using a chisel and hammer, bend the flywheel bolt locks into position.
4. Install the blower fan, install the bolts and tighten to 25–28 ft.–lbs. (34–38
Nm) torque (Fig. 7B–56).
B–06007
5. Install the U–joint coupler, install the bolts and tighten to 23–25 ft.–lbs.
(31–34 Nm) torque (Fig. 7B–55). Fig. 7B–57 Flywheel Bolt Locks
6. Install the engine in the loader (See Paragraph 7B–3.2).
B–05979
Fig. 7B–58 Flywheel Bolts
540, 543 Loader

7B–4 CYLINDER HEAD
7B–4.1 Removing The Cylinder
Head
NOTE: For easier removal of the

cylinder head the engine
can be removed from the
loader (See Paragraph
7B–3.1).

the following procedure: B–05094 B–05882
Fig. 7B–59 Valve Cover Fig. 7B–60 Fuel Injector Tubelines
MEL1181 – Nozzle Socket
1. Remove the nuts from the valve

cover.
2. Remove the valve cover (Fig.

7B–59).
3. Disconnect the fuel injection

tubelines (Fig. 7B–60).

4. Remove the injector nozzles
and the copper gaskets (Fig.
7B–61).
B–04091
5. Remove the intake manifold.
Fig. 7B–61 Injector Nozzles
6. Remove the belt shield.
7. Remove the alternator.
8. Remove the rocker arms (Fig.

7B–62).
9. Remove the valve rotators.
B–05093
Fig. 7B–62 Rocker Arms
10. Remove the push rods (Fig.

7B–63).
11. Remove the water return pipe.
12. Remove the cylinder head

bolts.
13. Remove the cylinder head from

the engine block (Fig. 7B–64).
14. Remove the head gasket and

the O–ring from the engine
block (Fig. 7B–65). B–05881 B–05101
Fig. 7B–63 Push Rods Fig. 7B–64 Cylinder Head
540, 543 Loader

NOTE: There may be a shim under
the cylinder head gasket.
Use the shim over again or
replace it with the same
size shim.
7B–4.2 Disassembly Of The

Cylinder Head
MEL10121 Valve Tool
B–05886 B–05889
Fig. 7B–65 Head Gasket Fig. 7B–66 Valve Tool
1. Using a valve compression tool
(Fig. 7B–66), remove the valve
cap and the valve spring collet
(Fig. 7B–67). Valve
2. Remove the valve spring. Spring

3. Remove the seal on the valve
and remove the valve from the Seal
cylinder head. Collets

4. Repeat this procedure for all the
valves.
5. Remove the thermostat Retainer Cap B–04122

housing and the thermostat
from the cylinder head (Fig. Fig. 7B–67 Valve Parts
7B–68).
7B–4.3 Servicing The Cylinder

Head
1. Clean the surface of the

cylinder head.
2. Put a straight edge on the

cylinder head (Fig. 7B–69).
NOTE: Do not put the straight

edge across the B–03643 A–02735
combustion chamber. Fig. 7B–68 Thermostat Fig. 7B–69 Checking Head Surface
3. Put a feeler gauge between the straight edge and the surface of the cylinder
head.
4. The maximum distortion of the cylinder head surface is ±0.002 inch (±0,05
mm).
5. If the measurement is more than the specification, remove the combustion

chambers then grind the cylinder head. Grind the same amount of material
from the bottom of the combustion chambers as was removed from the
head.
6. Clean the surface of the valve seat area.
7. Measure the width of the valve seat (Fig. 7B–70). B–03632

Fig. 7B–70 Checking Valve Seat
Revised Feb. 89 540, 543 Loader

8. The correct width of the valve
seat is 0.083 inch (2,1 mm) and Valve Contacting
the seat angle is 45 degrees. A C Width
9. Use the following steps to grind B

the valve seats (Fig. 7B–71).
Item A – Use a 45° cutter to grind the

surface of the valve seat.
Item B – Use a 15° cutter to grind the
front surface of the valve
seat.
Corrected Surfaced Uncorrected Surface
Item C – Use a 65° or 70° cutter to of Valve Seat of Valve Seat
grind the rear surface of the
valve seat to finish the seat A–45° cutter
to a 0.083 inch (2,1 mm) B–15° cutter
width. C–65° or 70° cutter A–02729
Item D – Grind the valve surface to a Fig. 7B–71 Grinding The Valve Seat
45° angle.
10. Install the valve in the seat and check the depth (Fig. 7B–72).
11. The specifications for the depth of the valve is 0.035–0.043 inch (0,9–1,1

mm).
NOTE: If the measurement is more than the specification add the correct
thickness washer under the valve spring to keep the correct tension
on the spring.
12. Clean the valve guide.
13. Install the valve in the cylinder head.
14. Install a dial indicator gauge.
15. Measure the clearance of the valve guide and the valve (Fig. 7B–73).
16. The measurement must be 0.0014–0.0026 inch (0,035–0,065 mm). Replace

the valve guide and valves as needed.
17. Measure the valve spring (Fig. 7B–74). The length of the spring must be
1.382–1.402 inch (35,1–35,6 mm). Replace the valve spring if it does not
meet this specification. B–03634
Fig. 7B–72 Checking Valve Depth
B–03698 B–03696
Fig. 7B–73 Checking Valve Guide Fig. 7B–74 Valve Spring Length
540, 543 Loader

18. Check the valve spring with a square to make sure it is straight (Fig. 7B–75).
Replace the spring if it is not straight.
19. Put the valve spring in a tester (Fig. 7B–76).
20. Push down on the spring 1.220 inches (31 mm). The compression load must
be 16.5 lbs. (7,49 kg). Replace the valve spring if it does not meet these
specifications.
21. Measure the inside diameter of the rocker arm bushing and the shaft
diameter (Fig. 7B–77).
22. The inside diameter of the rocker bushing is 0.4330–0.4340 inch

(10,997–11,038 mm). The rocker arm shaft diameter is 0.4320–0.4324 inch B–03680
(10,973–10,984 mm). If the measurements are not within the specifications Fig. 7B–75 Valve Spring Height
replace the parts as needed.
NOTE: If the cylinder head is to be

replaced, screw plugs
must be installed before
assembly.
7B–4.4 Assembly Of The Cylinder

Head

1. Install the valves.
2. Put oil on the valve seal and

install the valve seal on the A–02759 B–03697
valve. Fig. 7B–76 Valve Spring Compression Fig. 7B–77 Rocker Arm & Bushing
3. Install the valve spring and the
retainer.
4. Install the spring collet and the

valve cap.
5. Install the thermostat.
6. Install a new gasket and the

thermostat housing.
7B–4.5 Installing The Cylinder

Head B–05890 B–05886
Fig. 7B–78 Installing O–ring Fig. 7B–79 Installing Head Gasket
1. Install a new O–ring on the
engine block (Fig. 7B–78).
2. Install a new head gasket and

shim if there was a shim
removed (Fig. 7B–79).
3. Install the cylinder head on the

engine block.
4. Put oil on the cylinder head

bolts and nuts and tighten to
29–33 ft.–lbs. (40–44 Nm)
torque. Use the same
tightening sequence as shown
in figure 7B–80.
A–02773
Fig. 7B–80 Torque Sequence

5. Lower the piston which is to be measured for the clearance between the
cylinder head and the piston.
6. Put a piece of solder in the injector port (Fig. 7B–81). Make sure the solder
does not touch the valves.
7. Turn the engine with your hand until the piston goes over TDC.
8. Remove the solder and measure it. The thickness must be 0.024–0.031 inch
(0,6–0,8 mm). If the measurement is not within this specification, remove the
cylinder head and install the correct shim between the cylinder head and the
engine block.
9. Install the cylinder head and tighten the bolts and nuts to 29–33 ft.–lbs. B–04068
(40–44 mm) torque (Fig. 7B–80). Fig. 7B–81 Checking Top Clearance
10. Install the push rods.
11. Install the rocker arms.
12. Install the alternator, belt and shield.
13. Install the intake manifold.
14. Install the injector nozzles with a new copper gasket (See Paragraph
7B–2.5).

15. Install the injector high pressure tubelines.
16. Make sure the piston is at TDC when making the adjustment and adjust the
clearance to 0.0057–0.0073 inch (0,145–0,185 mm) cold (Fig. 7B–83). B–05893
Fig. 7B–82 Valve Adjustment
17. Adjust the valve clearance (Fig. 7B–82).
18. Install the valve cover with a new gasket. 0.0057–0.0073”

(0,145–0,185 mm)
NOTE: Retighten the cylinder head bolts and nuts to the correct torque
after the engine has been operated for 30 minutes.
A–02730
Fig. 7B–83 Valve Clearance
7B–4.6 Adjusting the Compression Release Mechanism

The compression release lever is used for the purpose of decreasing the
compression for cold weather starting, but normally is not used.
To adjust the compression release mechanism, use the following procedure:
1. Remove the compression release covers from the valve cover.
2. Adjust the exhaust valve in the fully closed position.
3. Loosen the locknut and turn the adjustment bolt out (Fig. 7B–84).
B–03650
4. Put the compression release lever in the compression release position. Fig. 7B–84 Adjusting Compression
Release

5. Turn the adjustment bolt
clockwise until it contacts the Compression Release Window Cover Compression
rocker arm. From this position Release
turn the adjustment bolt 1 to 1.5 Position
turns clockwise to get the
correct clearance (Fig. 7B–85).
Make sure the adjustment is
made to each exhaust valve.
6. Tighten the locknut and make

sure that the compression
release clearance is not too
wide. Turn the engine by hand, 0.0295–0.0443”
check to see that the valves do (0,75–1,125 mm) A–02762
not touch the top of the pistons.
Fig. 7B–85 Compression Release Specifications
7. Install the covers on the valve
cover.
DO NOT engage the

compression release lever
when the engine is running.
To do so will cause serious
damage to the engine.
B–05092 B–04717
Fig. 7B–86 Engine Tappets Fig. 7B–87 Removing The Starter
7B–5 REPAIRING THE ENGINE

See Paragraph 7B–4.1 to remove the
cylinder head. Then remove the
tappets from the engine block (Fig.
7B–86) and the starter (Fig. 7B–87).
See Paragraph 7B–2.3 to remove the
fuel injection pump.
B–03676 B–03647
Fig. 7B–88 Governor Spring Fig. 7B–89 Speed Control Plate
7B–5.1 Removing The Gear Case
1. Remove the governor spring from the governor fork (Fig. 7B–88).
2. Remove the plate for speed control and the governor spring (Fig. 7B–89).
3. Remove the start spring from the gear case (Fig. 7B–90).
4. Straighten the washer on the crankshaft sheave. Remove the nut and
washer.
B–03678
Fig. 7B–90 Start Spring
540, 543 Loader

5. Use a puller and remove the
crankshaft sheave (Fig.
7B–91).
6. Remove the key.
7. Remove the bolts from the gear

case.
8. Remove the gear case (Fig.

7B–92) and the O–ring.
B–05896 B–05895
Fig. 7B–91 Crankshaft Sheave Fig. 7B–92 Gear Case
7B–5.2 Removing The Timing

Gear, Camshaft & Oil Pump
1. Remove the crankshaft collar,

O–ring, oil slinger and the gear
collar (Fig. 7B–93).
2. Remove the snap ring on the

idler gear (Fig. 7B–94).
B–03637 B–05918
Fig. 7B–93 Crankshaft Collar Fig. 7B–94 Idler Gear Snap Ring
3. Remove the idler gear (Fig.

7B–95).
4. Remove the idler collar from the

shaft.
5. Make alignment of the hole in

the gear on the camshaft with
the stop plate bolts.
6. Remove the bolts for the

camshaft stop (Fig. 7B–96).
B–03699 B–05930
Fig. 7B–95 Idler Gear Fig. 7B–96 Camshaft Bolts
7. Remove the camshaft (Fig.

7B–97).
8. Remove the two bolts that hold

the fork lever on the fuel
camshaft.
9. Remove the fork lever (Fig.

7B–98).
B–03655 B–05919
Fig. 7B–97 Camshaft Fig. 7B–98 Fuel Camshaft Fork
540, 543 Loader

10. Remove the stop for fuel
camshaft (Fig. 7B–99, Item 1).
11. Remove the fuel camshaft and

gear (Fig. 7B–99, Item 2).
12. Straighten the washer on the

gear of the oil pump.
13. Remove the bolt on the gear of

the oil pump.
14. Remove the pump gear (Fig.

7B–100). B–05922 B–05923
Fig. 7B–99 Fuel Camshaft Fig. 7B–100 Oil Pump Gear
15. Remove the oil pump bolts and
the oil pump (Fig. 7B–101).
16. Remove the crankshaft gear

with a puller (Fig. 7B–102).
17. Remove the key.
7B–5.3 Removing Pistons And

Crankshaft

1. Remove the oil pan (Fig.
7B–103).
B–05925 B–03686
2. Remove the oil tube and screen
(Fig. 7B–104). Be careful do not Fig. 7B–101 Oil Pump Fig. 7B–102 Crankshaft Gear
damage the O–ring.
3. Remove the connecting rod

bolts.
4. Remove the cap and the

bearing from the connecting rod
(Fig. 7B–105).
5. Remove the piston from the

engine block (Fig. 7B–106).
NOTE: Make sure the pistons are

marked so they will be
returned to the same B–05924 B–05920
cylinder. Fig. 7B–103 Oil Pan Fig. 7B–104 Oil Tube And Screen
6. Straighten the washers on the

flywheel bolts.

flywheel.
8. Use a puller to remove the

flywheel.
B–03688 B–03625
Fig. 7B–105 Connecting Rod Cap Fig. 7B–106 Pistons
540, 543 Loader

bolts that hold the main bearing
in position.
10. Remove the main bearing bolts

from the engine block (Fig.
7B–107).

bolts that hold the main bearing
cover in position.
12. Remove the bolts (Fig.

7B–108). B–03644 B–03648
Fig. 7B–107 Main Bearing Bolt Fig. 7B–108 Bearing Cover
13. Install two bolts in the cover and
pull the cover out (Fig.
7B–108).
14. Remove the crankshaft from

the rear of the engine (Fig.
7B–109). Make sure you do not
damage the crankshaft.

bolts of the main bearings.

16. Remove the bolts (Fig.
7B–110).
17. Remove the bearing halves of

the main bearings. B–04126 B–04092
Fig. 7B–109 Removing Crankshaft Fig. 7B–110 Removing Main Bearings
7B–5.4 Servicing The Timing Gear

And The Camshaft
1. Measure the camshaft bearing

on the engine block (Fig.
7B–111). The specifications are
1.2992–1.3002 inch
(33,00–33,025 mm). The
allowable wear limit is
0.002–0.0036 inch (0,05–0,09
mm).
2. Measure the camshaft journals

(Fig. 7B–112). The
specifications are
1.2966–1.2972 inch
(32,934–32,950 mm). The
allowable wear limit is
0.002–0.0036 inch (0,05–0,09
mm).
3. If the measurements are not

within the specifications
replace the needed parts.
4. Put the camshaft on V–blocks.
5. Put a dial gauge on the journal.
B–03620 A–02761
Fig. 7B–111 Camshaft Bearing Fig. 7B–112 Camshaft
6. Turn the camshaft at a slow rate
(Fig. 7B–113). The allowable
wear limit is 0.0031 inch (0,08
mm).
7. If the camshaft measurements

are more than the
specifications, replace the
needed part.
8. Make a measurement of the

highest point on each lobe (Fig.
7B–114).
A–02760 B–05001
9. The specifications are 1.058 Fig. 7B–113 Camshaft Alignment Fig. 7B–114 Camshaft Lobe
inch (26,88 mm). The allowable
mm).
NOTE: After the crankshaft is

installed, check the
clearance for the camshaft
gear.
10. Install a dial gauge (Fig.

7B–115).

11. Hold one gear while turning the
other gear.
12. The specifications are B–03672 B–03621

0.0017–0.0045 inch
(0,042–0,115 mm). The Fig. 7B–115 Gear Clearance Fig. 7B–116 Piston Assembly
allowable wear limit is 0.0079
(0,2 mm).
7B–5.5 Servicing The Connecting Rods And Pistons
1. Remove the piston rings.
2. Remove the piston pin (Fig. 7B–116).
NOTE: Make sure to mark the piston and the connecting rod so they are
assembled the correct way.
A–02733
3. Measure the piston pin hole with an inside micrometer (Fig. 7B–117). Fig. 7B–117 Piston Pin Hole
4. The specifications are 0.7874–0.7879 inch (20,00–20,013 mm). The

allowable wear limit is 0.7886 inch (20,03 mm).
5. Measure the piston pin with a micrometer (Fig. 7B–118) and the connecting
rod bushing.
6. The new engine specifications are 0.006–0.0015 inch (0,014–0,038 mm).

Service replacement parts specifications are 0.0006–0.0026 inch
(0,015–0,066 mm). The allowable wear limit is 0.0059 inch (0,15 mm).
7. Put the piston ring in the engine block cylinder. Use a piston to push the ring
to the bottom of the cylinder bore.
B–03633
Fig. 7B–118 Connecting Rod Bushing

8. Measure the clearance with a
feeler gauge (Fig. 7B–119).
9. The specifications are as listed

below:
Top Ring – 0.0079–0.0138 inch

(0,20–0,35 mm).
Second Ring – 0.0118–0.0177 inch
(0,30–0,45 mm).
Oil Ring – 0.0098–0.0157 inch
(0,25–0,40 mm). B–03622
The allowable wear limit for all the Fig. 7B–119 Piston Ring Gap
rings is 0.0492 inch (1,25 mm).
10. Install the connecting rod on the B–04067

tool (Fig. 7B–120) and check Fig. 7B–120 Connecting Rod Alignment
for correct alignment.
NOTE: Check the I.D. of the

connecting rod bushing
because it is used for this
check, make sure it is not

worn.
11. The specifications are 0.0008

inch (0,02 mm). The allowable A–02763
mm). Fig. 7B–121 Crankshaft Alignment
7B–5.6 Servicing The Crankshaft
1. Put the crankshaft in V–blocks (Fig. 7B–121).
2. Put a dial gauge on the center journal. Turn the crankshaft at a slow rate.
3. The specifications are 0.0008 inch (0,02 mm). The allowable wear limit is B–03631
0.0031 inch (0,08 mm). Fig. 7B–122 Main Bearing Clearance
4. Measure the No. 1 main bearing (Fig. 7B–122). The specifications are
1.7317–1.7339 inch (43,984–44,040 mm).
5. Measure the No. 1 main bearing journal (Fig. 7B–123). The specifications
are 1.7296–1.7303 inch (43, 943–43,950 mm). The clearance between the
bearing and the journal must be 0.0013–0.0042 inch (0,034–0,106 mm) and
the allowable wear limit is 0.0079 (0,2 mm). Replace as needed.
B–03618
Fig. 7B–123 Crankshaft Main Bearing
Revised Feb. 89 540, 543 Loader

6. Put a piece of plastic gauge on the crankshaft main bearing (Fig. 7B–124).
7. Install the main bearing on the journal and tighten the bolts to 21–25 ft.–lbs.
NOTE: DO NOT turn the bearing.
8. Remove the main bearing and measure the plastic gauge (Fig. 7B–124).
9. Remove the bearing, measure the plastic gauge with the paper gauge and
if the measurement is over the allowable limits, replace as needed.
B–04065
10. The specifications for the outside diameter of the crankshaft journal is Fig. 7B–124 Main Bearing Clearance
1.7297–1.7303 inch (43,934–43,950 mm). The inside diameter of bearing is
1.7317–1.7339 inch (43,984–44,026 mm). The allowable wear limit between
the two items is 0.0079 inch (0,20 mm).
11. Measure the connecting rod bearings (Fig. 7B–125). The specifications are
1.4569–1.4587 inch (37,004–37,050 mm).
12. Measure the connecting rod journal (Fig. 7B–126). The specifications are
1.4551–1.4557 inch (36,959–36,975 mm). The allowable wear limit between 120°
the two items is 0.0079 inch (0,2 mm).
13. If the journals are not to specifications, grind the crankshaft. See

Specifications Page 8B–6 for the correct specifications (Fig. 7B–127).
14. When the crankshaft is installed, the end play must be checked (Fig.
7B–128). If the end play is more than 0.0059–0.0122 inch (0,15–0,31 mm)
replace the thrust bearing on the main bearing. A–02727
Fig. 7B–125 Checking Rod Bearing
NOTE: If crankshaft is to be
replaced install plugs in A
correct holes before
installing crankshaft in
cylinder block.
B
A–02716 A–02716
Fig. 7B–126 Connecting Rod Journal Fig. 7B–127 Connecting Rod Journal
7B–5.7 Servicing The Cylinder

Liners
1. Use a micrometer to measure

the inside of the cylinder liners
(Fig. 7B–129).
B–10072 B–04066
Fig. 7B–128 Crankshaft End Play Fig. 7B–129 Cylinder Wear
Revised Aug. 85 540, 543 Loader
2. To find the maximum wear, measure the inside diameter of the cylinder liner
in three different locations (Fig. 7B–130). The inside diameter specifications
on the cylinder liner is 2.9528–2.9535 inch (75,00–75,019 mm). The
allowable wear limit is +0.0059 inch (+0,15 mm).
3. When the cylinder has more wear than the specifications, bore and hone the A
cylinder to an oversize diameter (See Specifications Section 8B–2). B
NOTE: Make sure you use the correct oversize pistons and rings.
4. When the cylinder wear is more than wear limit, replace the cylinder liner.
These are dry liners.
5. Remove the cylinder liners. 1
6. Clean and put oil in the bore of the engine block.
7. Clean and put oil on the outside of the cylinder liner.

2
8. Install the cylinder liner into the engine block with the chamfered end down.
9. After installation of the cylinder liner, bore or hone the cylinder to standard
size (See Specifications Section 8B–2.8, Page 8B–4).
3

A–02717
Fig. 7B–130 Cylinder Measuring Points
7B–5.8 Servicing The Oil Pump
1. Use a feeler gauge to check the clearance between the inner and the outer
rotor (Fig. 7B–131).
2. The clearance for the inner rotor is 0.0039–0.0063 inch (0,099–0,160 mm).
The allowable wear limit is 0.0079 inch (0,2 mm).
B–03616
Fig. 7B–131 Oil Pump
3. Use a feeler gauge to check the clearance between the outer rotor and the
body of the oil pump (Fig. 7B–132).
4. The clearance for the outer rotor is 0.0043–0.0075 inch (0,11–0,19 mm).
5. At rated engine RPM, the oil pressure is 28 to 64 PSI (196 to 441 kPa). It
must not be any lower than 10 PSI (69 kPa) at engine idle RPM.
A–02732
Fig. 7B–132 Oil Pump
540, 543 Loader

7B–5.9 Servicing The Water Pump
1. Remove the coolant.
2. Remove the water pump (Fig.

7B–133).
3. Remove the sheave and the

snap ring.
4 2
4. Use a hydraulic press to
remove the hub shaft and 3 1
bearing assembly from the B–05926
impeller end.
Fig. 7B–133 Water Pump
5. Remove the old seal from the (1) Water Pump Impeller
pump body. (2) Seat Set
(3) Water Pump Body
(4) Bearing B–05929
6. Use a press to install a new seal into the body. Do not damage the seal.
Fig. 7B–134 Water Pump Assembly
7. If the bearings are defective, replace the entire bearing and shaft assembly.
8. Use a press to install the bearing and shaft into the pump body. Press until
the bearing is even with the pump flange. Do not press too far; the pump
body will break.

9. Press the impeller onto the shaft. Correct clearance between impeller vanes
and pump body is 0.030 inch (0,76 mm).
7B–6 ASSEMBLY OF THE ENGINE

7B–6.1 Installing The Crankshaft
1. Install the main bearings on the crankshaft journals. Tighten the bolts to Main
15–17 ft.–lbs. (29–34 Nm) torque. Bearing
Case
2. Install the thrust bearing with the oil grooves to the outside.
Case
3. Install the crankshaft in the engine. Make sure the holes in the main bearings Bolt
are in alignment with the holes in the engine block. The marks face toward A–02736
the flywheel. (Fig. 7B–135). Fig. 7B–135 Alignment Of Holes
4. Install the main bearing case bolts and tighten to 22–25 ft.–lbs. (64–69 Nm)
torque.
5. Install the new seals on the crankshaft rear cover.
6. Install the rear cover and tighten the bolts to 7–8 ft.–lbs. (9,5–11 Nm) torque.
7B–6.2 Installing The Pistons
NOTE: Make sure the marks on the piston and connecting rod are in the
same direction.
1. Install the rings on the piston (Fig. 7B–136). Position the top ring so gap is
not lined up with piston pin. Position the other rings so there is a gap every
90°.
2. Install the pistons in the engine block using a ring compressor. The alignment
marks must be opposite the camshaft. B–03614
Fig. 7B–136 Installing Rings

3. Align the bearing cap to the
connecting rod (Fig. 7B–137).
4. Put oil on the bolts and tighten

to 19–22 ft.–lbs. (27–30 Nm)
torque.
5. Install the oil pump tube and the

screen.
6. Put a new gasket on the oil pan

and install the oil pan.
A–02731 B–03658
Fig. 7B–137 Rod Bearing Cap Fig. 7B–138 Installing Oil Pump
7B–6.3 Installing The Camshaft

And Timing Gears
1. Install the oil pump and tighten

the bolts to 5–6 ft.–lbs. (8–9
Nm) torque (Fig.7B–138).
2. Install the gear and tighten the

nut.

3. Install the key and gear on the
crankshaft.
4. Install the fuel camshaft and B–03649 B–03655

fork lever (Fig. 7B–139). Fig. 7B–139 Fuel Camshaft Fig. 7B–140 Camshaft
5. Install the stop bolt on the fork

lever and tighten to 5–6 ft.–lbs.
(8–9 Nm) torque.
6. Install the bolts and tighten

13–15 ft.–lbs. (18–21 Nm)
torque.
7. Install the camshaft and tighten

the bolts to 14–15 ft.–lbs.
(18–21 Nm) torque (Fig.
7B–140).
8. Install the idler gear (Fig.

7B–141). B–03699 B–05927
Fig. 7B–141 Installing Idler Gear Fig. 7B–142 Timing Marks
9. The timing marks must be in correct alignment (Fig. 7B–142). Gear backlash
is 0.0017–0.0045 inch (0,043–0,114 mm). The allowable limit is 0.0079 inch
(0,2 mm).
10. Install the snap ring on the idler gear shaft.
11. Install the oil slinger. Put oil on the spring and install the O–ring and the collar
(Fig. 7B–143).
B–04098
Fig. 7B–143 Crankshaft Collar

7B–6.4 Installing The Gear Case
Cover
1. Install the three O–rings and

the oil seal in the gear case
cover (Fig. 7B–144). Put oil on
the oil seal.
2. Put a non–drying adhesive on

the edge of the gear case cover.
3. Install the gear case cover and Oil Seal

tighten the bolts to 13–15
ft.–lbs. (18–21 Nm) torque. B–03617 B–03678
Fig. 7B–144 Installing O–rings Fig. 7B–145 Start Spring
4. Install the start spring (Fig.
7B–145).
5. Install the speed control plate

and the governor spring (Fig.
7B–146).
NOTE: Make sure you do not drop

the governor spring into
the gear case.

6. Connect the governor spring
(Fig. 7B–147).
See Paragraph 7B–2.3 to install the

fuel injection pump. B–03647 B–03676
Fig. 7B–146 Speed Control Fig. 7B–147 Governor Spring
cylinder head on the engine block.
engine in the loader.
540, 543 Loader

540, 543 Loader

TECHNICAL DATA
Paragraph Page
Number Number
DECIMAL AND MILLIMETER EQUIVALENTS . . . . . . . . . 8C–3 8C–14
ENGINE SPECIFICATIONS
540 LOADER (KOHLER) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–2 8A–3
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–2.4 8A–3
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–2.5 8A–3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–2.3 8A–3
Cylinder Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–2.2 8A–3
Engine (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–2.1 8A–3
Engine Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–2.8 8A–4
Piston, Pin & Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–2.6 8A–3
Valves, Guides & Tappets . . . . . . . . . . . . . . . . . . . . . . . 8A–2.7 8A–3
ENGINE SPECIFICATIONS–
543 LOADER (KUBOTA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2 8B–3
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2.7 8B–3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2.11 8B–4
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2.8 8B–4
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2.3 8B–3

Engine Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2.14 8B–5
Fuel Injector Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2.1 8B–3
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2.2 8B–3
Grinding Specifications For The Crankshaft . . . . . . 8B–2.15 8B–6
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2.12 8B–4
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2.10 8B–4
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2.9 8B–4
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2.6 8B–3
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2.13 8B–4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2.4 8B–3
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2.5 8B–3
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS . 8C–2 8C–13

LOADER SPECIFICATIONS–540 . . . . . . . . . . . . . . . . . . . . . 8A–1 8A–1 TECHNICAL
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–1.6 8A–2 DATA
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–1.5 8A–2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–1.4 8A–2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–1.2 8A–1
Loader Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–1.3 8A–2
Operation & Performance . . . . . . . . . . . . . . . . . . . . . . . 8A–1.1 8A–1
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–1.7 8A–2
LOADER SPECIFICATIONS–543 . . . . . . . . . . . . . . . . . . . . . 8B–1 8B–1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–1.6 8B–2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–1.5 8B–2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–1.4 8B–2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–1.2 8B–1
Loader Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–1.3 8B–2
Operation & Performance . . . . . . . . . . . . . . . . . . . . . . . 8B–1.1 8B–1
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–1.7 8B–2
540, 543 Loader

TECHNICAL DATA (CONT’D)
Paragraph Page
Number Number
STANDARD TORQUE SPECIFICATIONS FOR BOLTS . 8C–5 8C–15
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 8C–1 8C–1

Bob–Tach & Lift Arm Group . . . . . . . . . . . . . . . . . . . . . 8C–1.6 8C–6
Brake, Chaincase & Axle Group . . . . . . . . . . . . . . . . . 8C–1.8 8C–8
Engine Group – 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–1.1 8C–1
Engine Group – 543 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–1.2 8C–2
Engine Group – 543 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–1.3 8C–3
Fuel System Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–1.4 8C–4
Hydraulic Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–1.9 8C–9
Hydrostatic Group – 540 . . . . . . . . . . . . . . . . . . . . . . . 8C–1.11 8C–11
Hydrostatic Group – 543 . . . . . . . . . . . . . . . . . . . . . . . 8C–1.12 8C–12
Operator Cab, Main Frame & Rear Door Group . . . 8C–1.10 8C–10
Seat Bar & Pedal Group . . . . . . . . . . . . . . . . . . . . . . . . 8C–1.7 8C–7
Steering Levers & Panel Group . . . . . . . . . . . . . . . . . . 8C–1.5 8C–5
U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . . . . . . 8C–4 8C–14
540, 543 Loader

8A–1 (540) LOADER SPECIFICATIONS
49.5
(1257)
97° 127.5
(3239)
62.5
102.5 (1588)
36° (2604)
18
(457) 42
85 (1067)
(2159)
72.5 32
(1842) (813) 51
(1308)
27°
24°
7.2 6.5 30
(183) 31 (165) (775) 38
(787) (965)

82 47.2
(2083) (1199)
104
(2642) PI–02583
Dimensions are given for loader equipped with standard Where applicable specifications conform to SAE
tires and dirt bucket and may vary with other bucket types. standard and are subject to change without notice.
All dimensions are shown in inches. Respective metric
dimensions are given in millimeters enclosed by
parentheses.
This loader was designed for use without counterweights or ballasts. The
manufacturer warns that changes of structure or weight distribution of the loader
can change the steering and also cause failure of loader parts.
8A–1.1 Operation & Performance
Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3250 lbs. (1474 kg)
Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 lbs. (363 kg)
Bucket Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 cu. ft. (0,2 m3)
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Infinitely variable 0–6.0 MPH
8A–1.2 ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kohler
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K582S
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline
Horsepower (Per SAE J602) . . . . . . . . . 22.5 HP (16,8 kW) (85% of Gross HP)
Maximum Governed RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3200 RPM
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 ft.–lbs. (56 Nm) @ 2200 RPM
Number Of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50 in. (88,9) 3.00 in. (76,2)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.7 cu. in. (945,5 cm3)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure System W/Filter
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry Replaceable Paper Element
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, battery ignition W/breaker points
Low Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900–1000 RPM
High Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3400 RPM ± 50 RPM

8A–1.3 Loader Hydraulics
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine driven, gear type
Pump Capacity . . . . . . . . . . . . . . . . . . . . . . . 8.5 GPM (31,4 L/min.) @ 3200 RPM
System Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1575 PSI (10860 kPa)
Filter . . . . . . Hydraulic replaceable cartridge in the return line from the oil cooler
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doubleacting

Bore Diameter
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 in. (50,8)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 in. (76,2)
Rod Diameter
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 in. (31,8)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 in. (38,1)
Stroke
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2 in. (563,9)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 in. (315)
Control Valve . . . . . . . . . . 3–spool, Series Type, Open Center W/float & detent
on lift & dent on auxiliary
Fluid Lines . . . . . . . . . . . . . . . . . . . SAE standard full flow tubes, hoses & fittings
Hydraulic Function Time:
Raise Lift Arms to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . 4.1 Seconds
Lower Lift Arms from Maximum Height . . . . . . . . . . . . . . . . . . . . . 3.5 Seconds
Move Bucket to Dump Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Seconds

Move Bucket to Retracted Position . . . . . . . . . . . . . . . . . . . . . . . . 1.9 Seconds
8A–1.4 Electrical
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 amp. flywheel
Battery . . . . . . . . . . . . . . . . . . . . 12 volt, 370 cold crank amps. @ 0°F.(–17,8 °C.)
106 min. reserve capacity
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, gear drive
8A–1.5 Drive System

Transmission . . . . . . . . . . . . . . . Hydrostatic infinitely variable, fully reversing (2)
Final Drive . . . . . . . . . . Chains & sprockets in seal crankcase with oil lubrication
8A–1.6 Capacities
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cooled
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 gal. (49 L)
Engine Lubrication W/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 qts. (3,8 L)
Hydraulic/Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 gal. (23 L)
(Includes 3.5 gal. (12,4 L) in the reservoir)
Chaincase Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 gal. (15 L)
8A–1.7 Tires
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.70 15, 4 Ply Rating
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45–50 PSI (310–345 kPa)
Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 x 8.50 – 15, 4 Ply Rating
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–37 PSI (228–255 kPa)

All dimensions are given in inches. Respective metric dimensions are given in
millimeters enclosed by parenthesis
8A–2 ENGINE SPECIFICATIONS – 540 LOADER (KOHLER)

8A–2.1 Engine (General)
Ignition Point Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.018–0.022 (0,46–0,56)
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025 (0,63)
Compression at Cranking Speed . . . . . . . . . . . . . . 100–120 PSI (689–827 kPa)
High Idle at No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3400 RPM
Low Idle at No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 RPM
Oil Pressure (Idle RPM) . . . . . . . . . . . . . . . . . . . . . . . . 40–50 PSI (276–345 kPa)
8A–2.2 Cylinder Bore

New Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50 (88,9)
Wear Diameter (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.503 (88,98)
Taper (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0015 (0,038)
Out–of–Round (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005 (0,127)
8A–2.3 Crankshaft
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004–0.010 (0,102–1,254)

Crankpin – New Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.625 (41,275)
Crankpin – Out–of–Round (Maximum) . . . . . . . . . . . . . . . . . . . . . 0.0005 (0,013)
Crankpin – Taper (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.001 (0,025)
Crankshaft Sleeve Bearing – Running Clearance . . . . . . . . . . . . . 0.0015–0.005
(0,038–0,127)
Crankshaft Journal Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.750 (44,45)
Crankshaft Journal Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 (0,076)
8A–2.4 Camshaft
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.017–0.038 (0,432–0,965)
Shaft to Bearing Clearance . . . . . . . . . . . . . . . . . . 0.0005–0.0035 (0,013–0,089)
8A–2.5 Connecting Rod

Big End – Wear Diameter (Maximum) . . . . . . . . . . . . . . . . . . . . . . 1.627 (41,326)
Rod to Crankpin – Clearance (Maximum) . . . . . . . . . . . . . . . . . . . 0.0035 (0,089)
Small End – New Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.875 (22,246)
Rod to Piston Pin – Clearance . . . . . . . . . . . . . . 0.0003–0.0008 (0,008–0,020)
Side Play on Crankpin . . . . . . . . . . . . . . . . . . . . . . . . 0.005–0.014 (0,127–0,356)
8A–2.6 Piston, Pin And Rings

*Thrust Face – Wear Diameter (Maximum) . . . . . . . . . . . . . . . . 3.4945 (88,760)
*Thrust Face to Bore – Clearance (Maximum) . . . . 0.007–0.010 (0,178–0,254)
Ring–Side Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.006 (0,152)
Ring–End Gap in Used Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 (0,762)
Pin to Boss Clearance (Loose) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0005 (0,013)
Pin to Rod Clearance . . . . . . . . . . . . . . . . . . . . . . . 0.0003–0.0008 (0,008–0,020)
*Measured Just Below the Oil Ring at Right Angles to Pin.

540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–SpecificationsSection8APages1–4
8A–2 ENGINE SPECIFICATIONS – 540 LOADER (KOHLER) (Cont’d)

8A–2.7 Valves, Guides & Tappets
Intake Valve to Tappet Clearance (Cold) . . . . . . . . . 0.008–0.010 (0,203–0,254)
Exhaust Valve to Tappet Clearance (Cold) . . . . . . . 0.017–0.020 (0,432–0,508)
Valve Lift – Zero Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.324 (8,230)
Intake Valve Stem to Guide Clearance (Maximum) . . . . . . . . . . . 0.0045 (0,114)
Exhaust Valve Stem to Guide Clearance (Maximum) . . . . . . . . . 0.0065 (0,165)
Tappet Clearance in Guide . . . . . . . . . . . . . . . . . . . 0.0012–0.0023 (0,030–0,058)
Guide Interference Fit in Block . . . . . . . . . . . . . . . . 0.0005–0.002 (0,013–0,051)
Guide Ream Diameter . . . . . . . . . . . . . . . . . . . . . . . . . 0.312–0.313 (7,925–7,95)
Valve Seat Angle (Degrees) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 (0,762)
8A–2.8 Engine Torque

Flywheel Retainer Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 ft.–lbs. (156 Nm)
Camshaft Retainer Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ft.–lbs. (54 Nm)
Oil Pan Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ft.–lbs. (41 Nm)
Manifold Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ft.–lbs. (34 Nm)
Closure Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ft.–lbs. (41 Nm)
*Connecting Rod Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 ft.–lbs. (22 Nm)

Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ft.–lbs. (27 Nm)
*Cylinder Head Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ft.–lbs. (48 Nm)
*Lightly Oiled Threads

8B–1 543 & 543B LOADER SPECIFICATIONS
49.5
(1257)
97° 127.5
(3239)
62.5
102.5 (1588)
36° (2604)
18
(457) 42
85 (1067)
(2159)
72.5 32
(1842) (813) 51
(1308)
27°
24°
7.2 6.5 30
(183) 31 (165) (775) 38
(787) (965)

82 47.2
(2083) (1199)
104
(2642) PI–02583
Dimensions are given for loader equipped with standard Where applicable specifications conform to SAE
tires and dirt bucket and may vary with other bucket types. standard and are subject to change without notice.
All dimensions are shown in inches. Respective metric
dimensions are given in millimeters enclosed by
parentheses.
This loader was designed for use without counterweights or ballasts. The
manufacturer warns that changes of structure or weight distribution of the loader
can change the steering and also cause failure of loader parts.
8B–1.1 Operation & Performance
Operating Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3270 lbs. (1483 kg)
Rated Operating Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 lbs. (363 kg)
Bucket Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 cu. ft. (0,2 m3)
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Infinitely variable 0–5.6 MPH
8B–1.2 ENGINE
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kubota
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D950–B
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Horsepower (Per SAE J816) . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5 HP (16,2 kW)
(Intermittent Net Brake Power)
Maximum Governed RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 RPM
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.5 ft.–lbs. (57,6 Nm) @ 1800 RPM
Number Of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.95 in. (74,9)/ 2.76 in. (70,1)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.6 cu. in. (928 cm3)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure System W/Filter
Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Dry Replaceable, Dual Paper Element
Low Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700–1000 RPM
High Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3150–3250 RPM

8B–1.3 Loader Hydraulics

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine driven, gear type
Pump Capacity . . . . . . . . . . . . . . . . . . . . . . . 8.0 GPM (30,3 L/min.) @ 3000 RPM
System Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1575 PSI (10860 kPa)
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic replaceable cartridge
in the return line from the oil cooler
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doubleacting
Bore Diameter
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 in. (50,8)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 in. (76,2)
Rod Diameter
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 in. (31,8)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 in. (38,1)
Stroke
Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2 in. (563,9)
Tilt Cylinder (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4 in. (315)
Control Valve . . . . . . . . . . 3–spool, Series Type, Open Center W/float & detent
on lift & dent on auxiliary
Fluid Lines . . . . . . . . . . . . . . . . . . . SAE standard full flow tubes, hoses & fittings
Hydraulic Function Time:
Raise Lift Arms to Maximum Height . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Seconds

Lower Lift Arms from Maximum Height . . . . . . . . . . . . . . . . . . . . . . 3.5 Seconds
Move Bucket to Dump Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Seconds
Move Bucket to Retracted Position . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 Seconds
8B–1.4 Electrical
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 amp. flywheel
Battery . . . . . . . . . . . . . . . . . . . . 12 volt, 370 cold crank amps. @ 0°F. (–17,8°C.)
106 min. reserve capacity
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt, gear drive
8B–1.5 Drive System

Transmission . . . . . . . . . . . . . . . Hydrostatic infinitely variable, fully reversing (2)
Final Drive . . . . . . . . . . Chains & sprockets in seal crankcase with oil lubrication
8B–1.6 Capacities
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 qts. (9 L)
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 gal. (49 L)
Engine Lubrication W/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 qts. (3,8 L)
Hydraulic/Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 gal. (23 L)
(Includes 3.5 gal. (12,4 L) in the reservoir)
Chaincase Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 gal. (15 L)
8B–1.7 Tires
Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.70–15, 4 Ply Rating
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45–50 PSI (310–345 kPa)
Floatation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 x 8.50 – 15, 4 Ply Rating
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 PSI (241 kPa)

8B–2 ENGINE SPECIFICATIONS
Engine compression @ 200 to 300 RPM
(Operating Temperature) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450 PSI (3103 kPa)
8B–2.1 Fuel Injector Nozzles

Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . 1990–2133 PSI (1372–1468 kPa)
Fuel Tightness Nozzle Seat . . . . . . . . . . . . . . 1848 PSI (12742 kPa) Dry Nozzle
8B–2.2 Fuel Injection Pump
Fuel Tightness of the Plunger . . . . . . . . . . . . . . . . . . 8 Sec.: initial pressure drop
from (58828–49023 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sec. or Less
Fuel Tightness of Delivery Valve . . . . . . . . . . . . . . . 10 Sec.: initial pressure drop
from 1422–71 PSI (9805–490 kPa)
Limit permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5–24.5 degrees B.T.D.C.
8B–2.3 Cylinder Head
Cylinder Distortion Limit . . . . . . . . . . . . . . . . 0.0020” (0,05 mm) in 4.0” (100 mm)
of the length of the cylinder head surface.
Thickness of Gasket . . . . . . . . . . . . . . . . . . . . . . 0.0413–0.0453” (1,05–1,15 mm)
Thickness of Gasket Shim . . . . . . . . . . . . . . . . . . . 0.0236–0.0315” (0,6–0,8 mm)
Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0236–0.0315” (0,6–0,8 mm)
Head Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48–51 ft.–lbs. (65–69 Nm)

8B–2.4 Valves
Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.083” (2,1 mm)
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees
O.D. of the Valve Stem . . . . . . . . . . . . . . . . . 0.2740–0.2746” (6,960–6,975 mm)
I.D. of the Valve Guides . . . . . . . . . . . . . . . . 0.2759–0.2765” (7,010–7,025 mm)
Clearance between Valve Stem & Guide . . . 0.0014–0.0026” (0,035–0,065mm)
Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004” (0,1 mm)
Depth of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.035–0.043” (0,9–1,1 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.051” (1,3 mm)
Valve Clearance (Cold) . . . . . . . . . . . . . . . . . 0.0057–0.0073” (0,145–0,185 mm)
8B–2.5 Valve Springs
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.382–1.402” (35,1–35,6 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.37” (34,8 mm)
Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2201” (30,09 mm)
Load to Compress to Fitted Length . . . . . . . . . . . . . . . . . . . . . 16.5 lbs. (7,49 kg)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 lbs. (6,36 kg)
Limit Permitted for Spring being Straight . . . . . . . . . . . . . . . . . . . 0.051” (1,3 mm)
8B–2.6 Rocker Arms
O.D. of Rocker Arm Shaft . . . . . . . . . . . . 0.4320–0.4324” (10,973–10,094 mm)
I.D. of Rocker Arm Bushings . . . . . . . . . . 0.4330–0.4346” (10,997–11,038 mm)
Clearance between Rocker
Arm Shaft & Bushings . . . . . . . . . . . . . . . . . . 0.005–0.0026” (0,013–0,065 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0047” (0,12 mm)
8B–2.7 Camshaft
O.D. of Camshaft Bearing Journal . . . . . 1.2966–1.2972” (32,934–32,950 mm)
I.D. of Camshaft Bearing . . . . . . . . . . . . . . 1.2992–1.3002” (33,00–33,025 mm)
Clearance between Camshaft
Bearing & Journal . . . . . . . . . . . . . . . . . . . . 0.0020–0.0036” (0,050–0,091 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059” (0,15 mm)
Alignment of the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0020” (0,05 mm)
Cam Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0583” (26,88 mm)
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . 0.0017–0.0045” (0,042–0,115 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0079” (0,2 mm)
540, 543 Loader

8B–2.8 Cylinders
I.D. of Cylinder Liner . . . . . . . . . . . . . . . . . . 2.9528–2.9535” (75,00–75,019 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.0059” (+0,015 mm)
I.D. of Oversized Liner . . . . . . . . . . . . . . . . . 2.9724–2.9732” (75,5–75,519 mm)
8B–2.9 Piston Rings
Ring Gap, Top Ring . . . . . . . . . . . . . . . . . . . . . . . 0.0079–0.0138” (0,20–0,35 mm)
Ring Gap, 2nd Ring . . . . . . . . . . . . . . . . . . . . . . . 0.0118–0.0177” (0,30–0,45 mm)
Ring Gap, Oil Ring . . . . . . . . . . . . . . . . . . . . . . . 0.0098–0.0157” (0,25–0,40 mm)
Side Clearance of Ring in Groove
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Can not Measure Accurately
2nd Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0033–0.0044” (0,085–0,112 mm)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 (0,5 mm)
8B–2.10 Piston
I.D. of Piston Bosses . . . . . . . . . . . . . . . . . . 0.784–0.7879” (20,00–20,013 mm)
O.D. of Piston Pin . . . . . . . . . . . . . . . . . . . 0.7875–0.7878” (20,002–20,011 mm)
I.D. of Connecting Rod Bushing
(Small End, Fitted) . . . . . . . . . . . . . . . . . 0.7884–0.7890” (20,025–20,040 mm)
Clearance Between Piston Pin &
Bushing (New Engine) . . . . . . . . . . . . . . . . 0.0006–0.0015” (0,014–0,038 mm)
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . 0.0006–0.0026” (0,015–0,066 mm)
Limited Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0059” (0,15 mm)

Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008” (0,02 mm)
Oversize Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020” (0,5 mm)
8B–2.11 Crankshaft
Crankshaft Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0008” (0,02 mm)
O.D. of Crankshaft Journals . . . . . . . . . . 1.7297–1.7303” (43,934–43,950 mm)
I.D. of Crankshaft Bearing No. 1 . . . . . . . 1.7317–1.7339” (43,984–44,040 mm)
I.D. of Crankshaft Bearing No. 2 . . . . . . . . 1.7317–1.7333 (43,984–44,026 mm)
Clearance Between Crankshaft Journal
& Bearing No. 1 . . . . . . . . . . . . . . . . . . . . . 0.0013–0.0042” (0,034–0,106 mm)
Clearance Between Crankshaft Journals
& Bearing No. 2 . . . . . . . . . . . . . . . . . . . . . 0.0013–0.0036” (0,034–0,092 mm)
O.D. of Connecting Rod Journals . . . . . . 1.4551–1.4557” (36,959–36,975 mm)
I.D. of Connecting Rod Bearings . . . . . . 1.4569–1.4587” (47,004–47,050 mm)
Clearance Between Connecting Rod
Journals & Bearing . . . . . . . . . . . . . . . . . . . . 0.0011–0.0036” (0,029–0,091 mm)
Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . 0.0059–0.0122” (0,15–0,31 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0197” (0,5 mm)
8B–2.12 Oil Pump
Oil Pressure @ Rated RPM . . . . . . . . . . . . . . . . . . . . . 28–64 PSI (196–441 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 PSI (196 kPa)
Oil Pressure @ Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 PSI (69 kPa)
Rotor Lobe Clearance . . . . . . . . . . . . . . . . . . . . . 0.0043–0.0059” (0,11–0,15 mm)
Clearance Between Outer Rotor &
Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0028–0.0059” (0,07–0,15 mm)
End Clearance Between Rotor & Cover . . . . . 0.0031–0.0051” (0,08–0,13 mm)
8B–2.13 Thermostat
Opening Temperature (Starting) . . . . . . . . . . . . 176.9°–182.3°F (80.5°–83.5°C)
(Full Open) . . . . . . . . . . . . . . . . . . . . . . . . . . 203°F (95°C)
Distance of Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3150” (8 mm)

8B–2.14 Engine Torque
Bolt material grades are shown by numbers punched on the bolt heads.
Before tightening, check the numbers shown below:
PUNCHED NUMBER BOLT MATERIAL GRADE

None Standard Bolts SS41, S20C
7 Special Bolts S43C, 248C (Refined)
9 Special Bolts SCM3, SCR3 (Refined)
BOLT TORQUES
MATERIAL GRADE STANDARD BOLT SPECIAL BOLT SPECIAL BOLT
NOMINAL DIAMETER SS41, S20C S43C,S48C (Refined) SCR3, SCM3 (Refined)
M6 5.8 to 6.9 ft.–lbs. 7.2 to 8.3 ft.–lbs. 9.0 to 10.5 ft.–lbs.
(7.8 to 9.3 Nm) (9.8 to 11.3 Nm) (12.3 to 14.2 Nm)
M8 13.0 to 15.2 ft.–lbs. 17.4 to 20.3 ft.–lbs. 21.7 to 25.3 ft.–lbs.

(17.7 to 20.6 Nm) (23.5 to 27.5 Nm) (29.4 to 34.3 Nm)
M 10 28.9 to 33.3 ft.–lbs. 35.4 to 41.2 ft.–lbs. 44.8 to 52.1 ft.–lbs.
(39.2 to 45.1 Nm) (48.0 to 55.9 Nm) (60.8 to 70.6 Nm)
(62.8 to 72.6 Nm) (77.5 to 90.2 Nm) (103.0 to 117.7 Nm)
(107.9 to 125.5 Nm) (123.6 to 147.1 Nm) (166.7 to 196.1 Nm)
(166.7 to 191.2 Nm) (196.1 to 225.5 Nm) (259.9 to 304.0 Nm)
(245.2 to 284.4 Nm) (274.6 to 318.7 Nm) (343.2 to 402.0 Nm)
(333.4 to 392.2 Nm) (367.7 to 431.5 Nm) (490.3 to 568.7 Nm)
*Cylinder Head Bolts And Nuts . . . . . . . . . . . . . . . . . . 48–51 ft.–lbs. (65–70 Nm)

Main Bearing Bolts (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ft.–lbs. (30 Nm)
*Main Bearing Bolts (Old) . . . . . . . . . . . . . . . . . . . . . . . 15–17 ft.–lbs. (20–24 Nm)
*Main Bearing Cage Bolts . . . . . . . . . . . . . . . . . . . . . . 22–25 ft.–lbs. (29–34 Nm)
*Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–43 ft.–lbs. (54–59 Nm)
*Connecting Rod Bolts . . . . . . . . . . . . . . . . . . . . . . . . . 20–22 ft.–lbs. (27–30 Nm)
*Rocker Arm Bracket Studs . . . . . . . . . . . . . . . . . . . . . 12–15 ft.–lbs. (17–21 Nm)
*Idler Gear Shaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 ft.–lbs. (9–11 Nm)
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–18 ft.–lbs. (20–25 Nm)
Drain Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30–36 ft.–lbs. (39–49 Nm)
Nozzle Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–36 ft.–lbs. (29–49 Nm)
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–15 ft.–lbs. (15–20 Nm)
Fuel Injection Tubeline Fittings . . . . . . . . . . . . . . . . . . 11–19 ft.–lbs. (15–26 Nm)
Crankshaft Pulley Nut . . . . . . . . . . . . . . . . . . . . . . 101–116 ft.–lbs. (137–157 Nm)
Injection Pump Vent Screw . . . . . . . . . . . . . . . . . . . . . 10–13 ft.–lbs. (14–18 Nm)
* Lightly Oiled Threads
8B–2.15 Grinding Specifications for the Crankshaft
540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–SpecificationsSection8BPages1–6
If the standard–size bearing cannot be used due to excessive wear of the crankpin and crank journals, use undersize or
oversize bearings.
3 C
1
A B

1 2
B–05928
REF. SIZE CODE NUMBER DESCRIPTION DIMENSION MARK

0.008 in. 15261–2391–1 Crankshaft 1.7218–1.7224 in. 020US
0,2 mm Bearing #1 43,743–43,750 mm
A
0,4 mm Bearing #1 43,534–43,550 mm
0,008 in. 15261–2393–1 Crankshaft 1.7218–1.7224 in. 020US
0,2 mm Bearing #2 43,734–43,750 mm
B
0,4 mm Bearing #2 43,534–43,550 mm
0,008 in. 15531–2297–1 Crankpin 1.4472–1.4478 in. 020US
0,2 mm Bearing 36,759–36,775 mm
C
0.016 in. 15531–2298–1 Crankpin 1.4393–1.4400 in. 040US
0,4 mm Bearing 36,559–36,575 mm
0,008 in. 15261–2397–1 Crank Side 0.9528–0.9547 in. 0.20 OS
0,2 mm 15261–2395–1 Bearing 24,20–24,25 mm
D
0.016 in. 15261–2398–1 Crank Side 0.9606–0.9626 in. 0.40 OS
0,4 mm 15261–2396–1 Bearing 24,40–24,45 mm
1 0.1300–0.1457 in.
3,3–3,7 mm
2 0.1102–0.1260 in.
2,8–3,2 mm
3 Oil hole must be 0.0394–0.0591 in. (1–1,5 mm) chamfer.
Use on oil stone to chamfer the oil hole.
540, 543 Loader

8C–1 TORQUE SPECIFICATIONS
8C–1.1 Engine Group – 540 Loader 4
Ref. Torque
1. 80–90 in.–lbs.
(9–10 Nm)
2. 15–17 ft.–lbs. 2
(21–23 Nm) 1 3
3. 25–28 ft.–lbs.
(34–38 Nm)
4. Adjust & Lock to give C–02765
the lever 6–10 ft.–lbs.
(9–13 Nm) tension.
5.* 25–28 ft.–lbs.
(34–38 Nm)
6.* 10–15 ft.–lbs.
(14–20 Nm)
7. 15–20 ft.–lbs.
(20–27 Nm)

8. 65–70 ft.–lbs. 3
1
(88–95 Nm)
9. 35–40 in.–lbs.
(4–5 Nm)
* Put LOCTITE on threads. 5

2
3 6
7 3
E–01440
2
8
2
1 9
E–01437
641, 642, 643 Loader

275 of 322 –8C–1– Service Manual
(Cont’d)
2
8C–1.2 Engine Group – 543 Loader
Ref. Torque
1. 25–28 ft.–lbs.
(34–38 Nm)
2. 15–17 ft.–lbs.
(21–23 Nm)
3. 9–11 ft.–lbs. 1
(12–15 Nm)
4. 65–70 ft.–lbs.
(88–95 Nm)
1
5. 40–45 ft.–lbs. 2
(54–60 Nm)
6.* 25–28 ft.–lbs.
(34–38 Nm)
7.* 23–25 ft.–lbs. 2
(31–34 Nm) 4
1

E–01405
8. 16–20 ft.–lbs.
(21–27 Nm)
9. 25–28 ft.–lbs.
(34–38 Nm)
*Put LOCTITE on Threads 3
3 9
2
7
5
1
7
6
6
E–01390
641, 642, 643 Loader

(Cont’d) 2
2 3
8C–1.3 Engine Group – 543 Loader
Ref. Torque
1
1. 80–90 in.–lbs.
(9–10 Nm)
2. 25–28 ft.–lbs.
(34–38 Nm)
3. Adjust & Lock to give
the lever 6–10 ft.–lbs.
(9–13 Nm) tension. 5
4. 55–70 in.–lbs. 1
(6–8 Nm)
5. 15–17 ft.–lbs. 4
(21–23 Nm) 2 5
D–01617
6. 40–60 ft.–lbs.
(54–81 Nm)
7. 35–40 in.–lbs.
(4–5 Nm) 1

1
5 5
E–01407
641, 642, 643 Loader

(Cont’d) 540 Loader
8C–1.4 Fuel System Group
Ref. Torque
1. 16–20 ft.–lbs.
(21–27 Nm)

E–01435
543 Loader
E–01404
641, 642, 643 Loader

(Cont’d)
8C–1.5 Steering Levers & Panel
Group
2
Ref. Torque
1. 25–28 ft.–lbs.
(34–38 Nm)
2. 16–20 ft.–lbs.
(22–27 Nm)
3. 21–25 ft.–lbs.
(28–34 Nm)
4. 11–13 ft.–lbs.
(15–18 Nm)
5. 18–20 ft.–lbs.
(24–27 Nm) 2
2
C–02762

4
1
4
1
3
3
3
3
4
1
4 1
5
1
E–01401
641, 642, 643 Loader

(Cont’d)
8C–1.6 Bob–Tach & Lift Arm
Group
Ref. Torque
1.* 25–28 ft.–lbs.
(34–38 Nm)
2. 40–50 ft.–lbs.
(54–68 Nm)
3. 16–20 ft.–lbs.
(22–27 Nm) 1
2
4. 125–140 ft.–lbs. 2
(170–190 Nm)
1
* Put LOCTITE on the Threads

C–02658
3 4
D–01280
641, 642, 643 Loader

(Cont’d)
8C–1.7 Seat Bar & Pedal Group
Ref. Torque
1. 25–28 ft.–lbs.
(34–38 Nm)
2. 9–12 ft.–lbs.
2
3
(12–15 Nm) 4 3
3. 40–58 ft.–lbs. 4
(54–61 Nm)
4. 16–20 ft.–lbs.
(22–27 Nm)
5. 18–20 ft.–lbs.
(24–27 Nm)
1
6. 11–13 ft.–lbs.
(15–18 Nm)

1
6
1 D–01548
1
1
1 6
D–01431
641, 642, 643 Loader

(Cont’d)
8C–1.8 Brake, Chaincase & Axle
Group
Ref. Torque
1. 16–20 ft.–lbs.
(22–27 Nm) 2 2
1
2. 65–70 ft.–lbs.
(88–95 Nm)
3. 260–300 ft.–lbs.
(325–407 Nm)
4. 25–28 ft.–lbs.
(34–38 Nm) 2
5. 100–110 ft.–lbs.
(136–149 Nm)
6.* 300–330 ft.–lbs.
(410–450 Nm)
7. 55–65 ft.–lbs.

(75–88 Nm)
8. 106–110 ft.–lbs.
(136–149 Nm)
D–01565
* Put LOCTITE on Threads 3
6
8
D–01616
C–02659
641, 642, 643 Loader

(Cont’d)
8C–1.9 Hydraulic Group
Ref. Torque
1. 11–13 ft.–lbs.
(15–18 Nm)
2
2. 16–20 ft.–lbs.
(22–27 Nm)
3. 31–33 ft.–lbs.
(42–45 Nm)
4. 25–28 ft.–lbs.
(34–38 Nm)

1
D–01284
1
1
D–01457
641, 642, 643 Loader

(Cont’d)
8C–1.10 Operator Cab, Main
Frame & Rear Door Group
Ref. Torque
1. 25–35 ft.–lbs.
(34–47 Nm)
2. 65–70 ft.–lbs. 4 3
(88–95 Nm)
3. 40–50 ft.–lbs.
(54–68 Nm)
4. 12–13 ft.–lbs.
(16–18 Nm)
5. 90–100 ft.–lbs.
(123–135 Nm) 1
6. 55–65 ft.–lbs.
(75–88 Nm)
E–01432
7. 15–17 ft.–lbs.

(21–23 Nm) 2
8. 80–90 in.–lbs.
(9–10 Nm)
8
7
D–01615
5
5 5
E–01443
641, 642, 643 Loader

(Cont’d)
8C–1.11 Hydrostatic Group–540
Loader
Ref. Torque
1. 65–70 ft.–lbs.
(88–95 Nm)
2. 15–17 ft.–lbs.
(21–23 Nm)
3. 25–28 ft.–lbs.
(34–38 Nm)
4. 16–20 ft.–lbs.
(22–27 Nm)

3 E–01442
E–01441
641, 642, 643 Loader

(Cont’d)
8C–1.12 Hydrostatic Group–543
Loader
Ref. Torque
1. 25–28 ft.–lbs.
(34–38 Nm)
2. 15–17 ft.–lbs.
(21–22 Nm)
3. 65–70 ft.–lbs.
(88–95 Nm)
4. 16–20 ft.–lbs.
(22–27 Nm)

2
1
E–01413
E–01410
641, 642, 643 Loader

8C–2 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
8C–2.1 Hydraulic/Hydrostatic Fluid
Use Clark hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not
available, use 10W–30 or 10W–40 SAE Motor Oil.
DO NOT use automatic transmission fluids in this loader or permanent damage
to the transmission will result.
Avoid contact with leaking hydraulic fluid

which under pressure can be forced through
the skin. Never check for leaks in a hydraulic
system with your bare hands. Use a piece of
wood or cardboard. If your skin is penetrated by
a fluid under pressure, consult a qualified
medical service.

Where temperatures below zero are common, loaders must be kept in a warm
building. Extra warm–up time must be used each time the loader is started during
cold temperature conditions. Cold fluid will not flow easily and it makes action of
the hydraulic function slower. Loss of fluid flow to the hydrostatic transmission
pump (indicated by TRANS light ON) will cause transmission damage in less than
60 seconds time.
Stop the engine if the TRANS light comes ON

and stays ON. The light indicates the loss of
fluid flow to the hydrostatic pumps which will
cause transmission damage in less than 60
seconds time.
I–2078–0895
641, 642, 643 Loader

8C–3 DECIMAL AND MILLIMETER EQUIVALENTS
FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 0.015625 — 0.397 33/64 0.515625 — 13.097
1/32 0.03125 — 0.794 17/32 0.53125 — 13.494
3/64 0.046875 — 1.191 35/64 0.546875 — 13.891
1/16 0.0625 — 1.588 9/16 0.5625 — 14.288
5/64 0.078125 — 1.984 37/64 0.578125 — 14.684
3/32 0.09375 — 2.381 19/32 0.59375 — 15.081
7/64 0.109375 — 2.778 39/64 0.609375 — 15.478
1/8 0.1250 — 3.175 5/8 0.6250 — 15.875
9/64 0.140625 — 3.572 41/64 0.640625 — 16.272
5/32 0.15625 — 3.969 21/32 0.65625 — 16.669
11/64 0.171875 — 4.366 43/64 0.671875 — 17.066
3/16 0.1876 — 4.762 11/16 0.6875 — 17.462
13/64 0.203125 — 5.159 45/64 0.703125 — 17.859
7/32 0.21875 — 5.556 23/32 0.71875 — 18.256
15/64 0.234375 — 5.953 47/64 0.734375 — 18.653
1/4 0.2500 — 6.350 3/4 0.7500 — 19.050
17/64 0.265625 — 6.747 49/64 0.765625 — 19.447
9/32 0.28125 — 7.144 25/32 0.78125 — 19.844
19/64 0.296875 — 7.541 51/64 0.796875 — 20.241
5/16 0.3125 — 7.938 13/16 0.8125 — 20.638
21/64 0.328125 — 8.334 53/64 0.828125 — 21.034
11/32 0.34375 — 8.731 27/32 0.84375 — 21.431
23/64 0.359375 — 9.128 55/64 0.859375 — 21.828

3/8 0.3750 — 9.525 7/8 0.8750 — 22.225
25/64 0.390625 — 9.922 57/64 0.890625 — 22.622
13/32 0.40625 — 10.319 29/32 0.90625 — 23.019
27/64 0.421875 — 10.716 59/64 0.921875 — 23.416
7/16 0.4375 — 11.112 15/16 0.9375 — 23.812
29/64 0.453125 — 11.509 61/64 0.953125 — 24.209
15/32 0.46875 — 11.906 31/32 0.96875 — 24.606
31/64 0.484375 — 12.303 63/64 0.984375 — 25.003
1/2 0.5000 — 12.700 1 1.000 — 25.400
1 mm = 0.03937’’ 0.001 = 0.0254 mm
8C–4 U.S. TO METRIC CONVERSION
TO CONVERT INTO MULTIPLY BY

LINEAR Miles Kilometers 1.609
MEASUREMENT Yards Meters 0.9144
Feet Meters 0.3048
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2.54
Inches Millimeters 25.4
AREA Square Miles Square Kilometers 2.59
Square Feet Square Meters 0.0929
Square Inches Square Centimeters 6.452
Acre Hectare 0.4047
VOLUME Cubic Yards Cubic Meters 0.7646
Cubic Feet Cubic Meters 0.02832
Cubic Inches Cubic Centimeters 16.39
WEIGHT Tons (Short) Metric Tons 0.9078
Pounds Kilograms 0.4536
Ounces (Avdp.) Grams 28.3495
PRESSURE Pounds/Sq. In. Kilopascal 6.895
WORK Foot–Pounds Newton–Meter 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LIQUID FLOW Gallons/Minute Liters/Minute 3.785
TEMPERATURE Fahrenheit Celsius 1.Subtract 32°
2. Multiply by 5/9
641, 642, 643 Loader
8C–5 STANDARD TORQUE SPECIFICATIONS FOR BOLTS
The following table shows standard torque specifications for bolts with zinc
phosphate coating. Bolts purchased from Clark that have zinc phosphate coating
are specified by the letter H following the part number.
THREAD SIZE SAE GRADE 5 SAE GRADE 8

0.250 80–90 110–120
INCH. (9–10) (13–14)
LBS.
(Nm) 0.3125 180–200 215–240
(21–23) (24–27)
0.375 25–28 35–40
(34–38) (48–54)
0.4375 40–45 60–65
(54–61) (82–88)
0.500 65–70 90–100
(88–95) (125–135)
0.5625 90–100 125–140
(125–135) (170–190)

0.625 125–140 175–190
(170–190) (240–260)
0.750 220–245 300–330
(300–330) (410–450)
FOOT
LBS. 0.875 330–360 475–525
(Nm) (450–490) (645–710)
1.0 475–525 725–800
(645–710) (985–1085)
1.125 650–720 1050–1175
(880–975) (1425–1600)
1.250 900–1000 1475–1625

(1200–1360) (2000–2200)
1.375 1200–1350 2000–2200
(1630–1830) (2720–2980)
1.500 1500–1650 2600–2850
(2040–2240) (3530–3870)
1.625 2000–2800 3450–3800
(2720–2980) (4680–5150)
1.750 2500–2750 4300–4800
(3390–3730) (5830–6500)
1.875 3150–3500 5500–6100
(4270–4750) (7450–8300)
2.0 3800–4200 6500–7200
(5150–5700) (8800–9800)
641, 642, 643 Loader

540(S/N501012001&Above),543(S/N502412001&Above),543B(S/N511111001&Above)ServiceManual#6566532–SpecificationsSection8CPages1–16
641, 642, 643 Loader

540–3
® Revision Number
29 August 1983
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT LOADER X
SERVICE MANAGER
Model 540, 543 SALES MANAGER
Manual No. 6566532 (1–83)
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
This Service Manual Revision adds the procedure to replace the dust and inner seal, in the mounting flange, for Motor (P/N
6599718) Model No. 109–1052–006.

Remove Pages 3–13 thru 3–18.
Add Pages Revised June 83 3–13 thru 3–18.
291 of 322
292 of 322
540–4
® Revision Number
17 October 1983
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6566532 (1–83)
The attached sheets are a revision to the Bobcat 540/543 (S/N 12000 & Above) Service Manual (P/N 6566532 1–83).

This Service Manual Revision contains the revised or added sheets plus 3 Electrical Charts. Insert charts in front of Section
6.
REMOVE INSERT
Hydrostatic System Index Page Hydrostatic System Index Page,
(Revised Oct. 83)
3–31, 3–32 3–31, 3–32 (Added Oct. 83)
Electrical Charts (Section 6)
6–5, 6–6 6–5, 6–6 (Revised Oct. 83)
6–6a, 6–6b (Revised Oct. 83)
7B–7, 7B–8 7B–7, 7B–8 (Revised Oct. 83)
293 of 322
294 of 322
540–5
® Revision Number
31 October 1983
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6566532 (1–83)
This revision for the 540, 543 Service Manual adds the Melroe Company Valve servicing procedure to the manual. New
Hydraulic and Hydrostatic Flow Chart for loaders starting with S/N 13001 are also included.

Take the following pages out of your Service Manual and put in the Added and Revised Pages as follows:
TAKE OUT PUT IN

SECTION 2
Section 2, Contents Section 2, Contents (Revised Oct. 83)
2–9, 2–10 * Hydraulic Flow Chart
2–9, 2–10 (Revised Oct. 83)
2–10a thru 2–10h (Added Oct. 83)
SECTION 3
* Hydrostatic Flow Chart
*Put these charts in the Manual after the Charts which are already in the Manual. Do not remove the Charts which are
already in the Manual.
295 of 322
296 of 322
540–6
® Revision Number
10 January 1984
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6566532 (1–83)
The attached sheets are a revision to the 540, 543 Service Manual (P/N 6566532). This revision includes new information
on Splined Shaft Char Lynn Motors.

Take out the folowing pages from the Service Manual and put in the revised pages as follows:
TAKE OUT PUT IN

3–9, 3–10 3–9 (Revised Dec. 83), 3–10
3–13 (Revised Aug. 83), 3–14 (Revised Aug. 83) 3–13 (Revised Dec. 83), 3–14 (Revised Dec. 83)
3–15 (Revised Aug. 83), 3–16 (Revised Aug. 83) 3–15 (Revised Dec. 83), 3–16 (Revised Dec. 83)
3–19, 3–20 3–19 (Revised Dec. 83), 3–20
297 of 322
298 of 322
540–7
® Revision Number
18 May 1984
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6566532 (1–83)
This Service Manual Revision will update the Hydraulic Flow Chart #6566782 (9–83) located in the front of the Hydraulic
Section of your Service Manual.

Remove Hydraulic Flow Chart #6566782 (9–83) and replace it with Hydraulic Flow Chart #6566782 (5–84).
299 of 322
300 of 322
540–8
® Revision Number
19 August 1985
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6566532 (1–83)
This revision adds procedures for checking Hydraulic Pump and Fuel Injection Pump, Window Bead Installation Tool and
Seat Bar Installation and system are also included.

This revision also includes Water pump Servicing and Engine Torque changes.
Take out the following pages in your Service Manual and replace with revised pages as follows:
TAKE OUT PUT IN

2–11, 2–12 2–11 (Revised Aug. 85), 2–12
Contents Section 5 Contents Section 5 (Revised Aug. 85)
5–11 5–11 (Added Aug. 85), 5–12 (Added Aug. 85)
5–13 (Added Aug. 85)
7B–3, 7B–4 7B–3 (Revised Aug. 85), 7B–3a (Added Aug. 85), 7B–4
7B–19, 7B–20 7B–19 (Revised Aug. 85), 7B–20
7B–27, 7B–28 7B–27 (Revised Aug. 85), 7B–28
7B–29, 7B–30 7B–29 (Revised Aug. 85), 7B–30
301 of 322
302 of 322
540–9
® Revision Number
17 February 1986
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6566532 (1–83)
The Operator Cab and Engine Electrical Charts have been combined.

Remove the old Electrical Chrts as listed and put in the new Electrical Charts.
TAKE OUT PUT IN

540 & 543 – Operator Cab Wiring Diagram (P/N 6566804)
Printed Sept. 83
540 – Engine Wiring Diagram (P/N 6566805) 540 – Wiring Diagram (P/N 6566805)
Printed Sept. 83 Printed Feb. 86
543 – Engine Wiring Diagram (P/N 6566806) 543 – Wiring Diagram (P/N 6566806)
Printed Sept. 83 Printed Feb. 86
303 of 322
304 of 322
540–11
® Revision Number
18 September 1986
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6566532 (1–83)
The attached page is a revision for the 540, 543 Service Manual (P/N 6566532).

Take out the folowing page and put in the revised page:
TAKE OUT PUT IN

3–19 (Revised Dec. 83), 3–20 3–19 (Revised Sept. 86), 3–20
305 of 322
306 of 322
540–13
® Revision Number
21 November 1988
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6566532 (1–83)
Remove the following pages from the 540, 543 Service Manual (P/N 6566532) and put in the revised or added pages.

TAKE OUT PUT IN
SECTION 2
HYDRAULIC FLOW CHART & System Operations HYDRAULIC/HYDROSTATIC FLOW CHART #6570999
(S/N 12000 & Up) (Printed November 1988)
SECTION 3
HYDROSTATIC FLOW CHART (Neutral Position)
(S/N 12000 & Up)
HYDROSTATIC FLOW CHART (Forward Position)
S/N 12000 & Up)
SECTION 6
CAB WIRING DIAGRAM #6720032 (S/N 22127 & Above)
(Printed November 1988)
307 of 322
308 of 322
540–14
® Revision Number
15 February 1989
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6566532 (1–83)
This is a revision to the 540 Service Manual (P/N 6566532). Remove the following pages and add the revised pages shown
below:

TAKE OUT PUT IN
7B–17, 7B–18 7B–17 (Revised Feb. 89), 7B–18
7B–25, 7B–26 7B–25, 7B–26 (Revised Feb. 89)
309 of 322
310 of 322
540–15
® Revision Number
9 August 1990
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6566532 (1–83)
This is a revision to the 540, 543 Service Manual (P/N 6566532).

Tke out and put in the revised page as listed below:
TAKE OUT PUT IN
3–29, 3–30 3–29 (Revised Aug. 90), 3–30
311 of 322
312 of 322
540–16
® Revision Number
21 August 1992
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6566532 (1–83)
Take out the following pages and put in the revised pages as follows:

TAKE OUT PUT IN
ENGINE WIRING DIAGRAM (P/N 6722299)
543 (S/N 25463 & Above)
(Printed August 1992)
313 of 322
314 of 322
540–17
® Revision Number
4 January 1995
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6566532 (11–94)
Take out the following pages and put in the revised and added pages as follows:

TAKE OUT PUT IN
COVER COVER
with S/N 20001 & Above with S/N 12001 & Above)
315 of 322
316 of 322
540–1 Thru 540–17
® Revision Number
15 October 1998
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6566532 (11–94)
This 540, 543 Service Manual includes all the Service Manual Revisions through 540–17.

Insert all future revisions in the manual.
317 of 322
318 of 322
540–18
® Revision Number
14 October 1998
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Model 540, 543 & 543B SALES MANAGER
Manual No. 6566532 (11–94)

TAKE OUT PUT IN
COVER COVER
MAINTENANCE SAFETY Page
(Place Behind Cover)
SAFETY INSTRUCTION Page SAFETY INSTRUCTION Page
1–9 thru 1–14 1–9 thru 1–14
1–19 1–19, 1–20
HYDRAULIC/HYDROSTATIC SYSTEM OPERATION HYDRAULIC/HYDROSTATIC SYSTEM OPERATION
To Be Used With To Be Used With
HYDRAULIC/HYDROSTATIC FLOW CHART HYDRAULIC/HYDROSTATIC FLOW CHART
For Model For Model
540, 543 (Starting With S/N 13001), 543B 540, 543 (Starting With S/N 13001), 543B
Chart # 6570283 (Printed October 94) Chart # 6570283 (Printed October 98)
2–10a, 2–10b 2–10a, 2–10b
2–10g, 2–10h 2–10g, 2–10h
2–27 2–27, 2–28
5–2a 5–2a, 5–2b
6–1 thru 6–4 6–1 thru 6–4
319 of 322
320 of 322
540–19
® Revision Number
3 November 1998
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6566532 (11–94)

TAKE OUT PUT IN
HYDRAULIC/HYDROSTATIC SYSTEM OPERATION HYDRAULIC/HYDROSTATIC SYSTEM OPERATION
To Be Used With To Be Used With
HYDRAULIC/HYDROSTATIC FLOW CHART HYDRAULIC/HYDROSTATIC FLOW CHART
For Model For Model
540, 543 (Starting With S/N 13001), 543B 540, 543 (Starting With S/N 13001), 543B
Chart #6570283 (Printed October 1998) Chart #6570283 (Printed November 1998)
321 of 322
322 of 322

540-543 6566532 SM 11-94

Uploaded by

Copyright:

Available Formats

540-543 6566532 SM 11-94

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

540-543 6566532 SM 11-94

Uploaded by

Copyright:

Available Formats

What safety precautions are mentioned?

What safety precautions are mentioned?

What maintenance procedures are discussed?

What maintenance procedures are discussed?

5 5

Dealer Copy -- Not for Resale

6566532 (11–94) Printed in U.S.A. © Melroe Company 1994

CORRECT CORRECT CORRECT

B-10731a B-12365 B-7469

Dealer Copy -- Not for Resale

B-6590 B-6580 B-6589

Dealer Copy -- Not for Resale

HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . 2–1

INTAKE & EXHAUST MANIFOLD . . . . . . . . . . . . . . 7A–1

LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1

540, 543 Loader

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

Dealer Copy -- Not for Resale

Revised Oct. 94 540, 543 Loader

Dealer Copy -- Not for Resale

540, 543 Loader

1. Check that the ROPS/FOPS 9. Enclosure door latches must

2. Check that ROPS mounting 10. Bob–Tach wedges and

Dealer Copy -- Not for Resale

5. Machine signs must be legible 13. Check hydraulic fluid level,

7. Check for correct function of 15. Lubricate the loader.

8. The parking brake must 16. Check the condition of the

540, 543 Loader

18. Check the electrical charging

19. Check tires for wear and

20. Inspect for loose or broken

Dealer Copy -- Not for Resale

22. Check for any field

Recommend to the owner that all

540, 543 Loader

Dealer Copy -- Not for Resale

Warnings on the machine and in the This notice identifies procedures

540, 543 Loader

Dealer Copy -- Not for Resale

540, 543 Loader

ENGINE SERVICE (General) . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 1–3

FINAL DRIVE TRANSMISSION (Chaincase) . . . . . . . . . . . . . 1–7 1–14

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 1–1

LUBRICATION OF THE LOADER . . . . . . . . . . . . . . . . . . . . . . 1–9 1–16

ROLLOVER PROTECTION STRUCTURE

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2 1–2

Dealer Copy -- Not for Resale

TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 1–15

TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . 1–11 1–17

DO NOT service the Bobcat loader

Revised Oct. 94 540, 543 Loader

540, 543 Loader

1–1.1 Serial Number Identification

1–1.2 Loader Serial Number

Dealer Copy -- Not for Resale

Production Sequence (Series)

1–1.3 Engine Serial Number