Bobcat S590 Skid-Steer Loader Service Manual 2021 – PDF Repair & Maintenance Guide

Description

The Bobcat S590 Skid-Steer Loader Service Manual is the full workshop reference for the S590 machine, written for the technicians who diagnose, strip, repair and reassemble the loader. It covers serial numbers B42E11001 & Above and B4U911001 & Above and runs close to a thousand pages across every major system on the machine, from the 2.4 L Bobcat turbocharged diesel and its diesel particulate filter and exhaust gas recirculation hardware, through the tandem hydrostatic pump and drive motors, the hydraulic control valve and cylinders, the chaincase and final drive, the controller network and complete wiring schematics, and the optional heating, ventilation and air conditioning package. This is not an owner’s summary. It is the shop manual a dealer technician works from, and it is the same document whether you are pulling a lift cylinder on a machine with 400 hours or calibrating a rebuilt hydrostatic pump on an SJC-equipped loader.

File Details

• Manual Type: Service Manual (workshop repair, maintenance and diagnostics)
• Brand: Bobcat
• Model: S590 Skid-Steer Loader
• Serial Numbers Covered: B42E11001 & Above, B4U911001 & Above (with B4ZE11001 & Above and B4RF11001 & Above referenced in the hydraulic and wiring schematic sets)
• Language: English
• Page Count: 969 pages
• File Format: PDF
• Document Number: 7417394enUS
• Wiring Schematic Sheets: 15 sheets (standard machine) and 17 sheets (SJC machine)

Chapters Covered

• Safety Instructions – fire prevention, electrical, hydraulic, fueling, starting, welding and grinding
• Maintenance – lifting and blocking, lift arm support, operator cab, transporting, towing, remote start tools, service schedule, engine air cleaner, engine cooling system, fuel system, engine lubrication, hydraulic/hydrostatic system, final drive transmission, Bob-Tach, lubrication points, tire maintenance, pivot pins, storage
• Hydraulic System – troubleshooting, glossary of hydraulic symbols, lift cylinder, tilt cylinder, Bob-Tach cylinder, main relief valve, standard hydraulic control valve, SJC hydraulic control valve, lift arm bypass control valve, hydraulic pump, high flow hydraulic pump, filters, fluid reservoir, oil cooler, bucket position valve, rear auxiliary diverter valve, Power Bob-Tach block, front auxiliary hydraulic coupler block, automatic ride control
• Hydrostatic System – hydrostatic drive motor, two-speed drive motor, hydrostatic motor carrier, two-speed motor carrier, charge pressure, hydrostatic pump, SJC hydrostatic pump, drive belt, two-speed valve block, drain manifold
• Drive System – brake, drive components, axle seals, axle/sprocket/bearings, drive chains, chaincase
• Mainframe – seat bar, operator cab, operator seat, suspension seat, Bob-Tach (hand lever and power), lift arms, rear grille, rear door, fuel tank, control pedals and linkages, control panel, SJC control panel, control handle/lever, access panels, rear window, top window, side window, cab door, armrest, lower panels, headliner, fan duct panels
• Electrical System – glossary of electrical symbols, cab and mainframe harness connectors, fuse and relay identification, battery, alternator, starter, instrument panel identification, lights, Gateway and Auxiliary controllers, SJC Drive controller, Engine Control Unit, diagnostic service codes, BICS, seat bar sensor, traction lock, electrical/hydraulic controls, Service PC, calibration, steering drift compensation, control panel setup, password setup, maintenance clock, back-up alarm, front horn, engine speed control, camshaft and crankshaft position sensors, Machine IQ
• Engine Service – engine information and specifications, sensor locations, torque values, troubleshooting, engine removal and installation, engine mounts, compression testing, injector signal testing, DPF system and regeneration, air cleaner, engine cooling system, lubrication system, fuel system, cylinder head, crankshaft and pistons, camshaft, gearcase, turbocharger, flywheel and housing, EGR system
• HVAC – air conditioning system flow, regular maintenance, troubleshooting trees, system charging and reclamation, compressor, condenser, receiver/drier, evaporator/heater unit, thermostat, expansion valve, evaporator coil, heater coil, blower fan, heater valve, evaporator/heater cover
• Specifications – loader dimensions, performance, engine, drive system, controls, hydraulic system, electrical system, capacities, tires, temperature range, torque specifications for SAE and metric bolts, hydraulic connection specifications, hydraulic/hydrostatic fluid specifications, conversions
• Index – alphabetical index and wiring schematic index

Read as a whole, the Bobcat S590 Skid-Steer Loader Service Manual gives a technician a complete working picture of the machine rather than isolated fragments. The maintenance section establishes the service intervals and the lubrication points that keep the loader running, the system chapters explain how each assembly is built and how to test it, and the specification and torque tables at the back give the values needed to put it back together correctly. The engine chapter alone runs from compression and injector signal testing through cylinder head measurement, piston class selection and gear timing, while the hydrostatic chapter covers pump teardown, charge pressure adjustment and mechanical and hydraulic neutral adjustment in the detail a rebuild demands.

Engine, Emissions and Powertrain Service

The engine material covers the Bobcat direct injected D24 DM02VB turbocharged and inter-cooled diesel used in the S590, including the sensor layout for the camshaft and crankshaft position sensors, water temperature, intake manifold pressure and temperature, oil pressure, rail pressure, inlet metering valve and EGR valve. Removal and installation of the engine and hydrostatic pump package is described step by step, along with engine mount replacement, compression testing with the correct adapter and gauge, and injector signal testing both at the connector and in-line. The diesel particulate filter chapter explains passive, automatic, forced, forced parked and service regeneration, the soot load tables that determine which regeneration is permitted, and the icons and service codes that go with each state. The fuel system section walks through the lift pump, transfer and high pressure pump, fuel temperature sensor, fuel cooler, fuel recirculation valve and injector removal, including the injector coding procedure that has to be written to the ECU after replacement.

Hydraulics, Hydrostatics and Drive

This is where the manual earns its keep. Cylinder chapters for lift, tilt and Bob-Tach include testing, removal, disassembly, parts identification and assembly with the correct tooling, seal installation orientation and torque values for the piston nut and gland. The hydraulic control valve is documented in both the standard and SJC versions, with exploded diagrams identifying the lift, tilt and auxiliary spools, load check valves, anti-cavitation valves, port relief valves, lock valves and solenoids, plus the removal and installation sequence for each. The hydraulic pump and high flow pump chapters give quick coupler and direct pump test procedures with the flow percentages that flag a failing pump, and the high flow relief valve adjustment. The hydrostatic side covers the drive motors, motor carriers, charge pressure testing and adjustment, and the hydrostatic pump with parts identification, disassembly and assembly, plus mechanical and hydraulic controller neutral adjustment. The chaincase, axle, sprocket, bearing and drive chain procedures close out the drive system.

Electrical, Controllers and Diagnostics

The electrical system is documented in unusual depth. A symbol glossary and harness connector maps for the standard cab, deluxe cab and mainframe harnesses precede the fuse and relay identification for both standard and SJC machines. Individual component chapters cover the battery, alternator with voltage and low/high voltage testing, and starter testing. The controller chapters cover the Gateway, Auxiliary, SJC Drive and Engine Control Unit with pin-by-pin connector identification, plus the Bobcat Interlock Control System inspection sequence, seat bar sensor testing with the sensor tester, and the traction lock. A full diagnostic service code list runs through the letter codes and the numeric codes, with the code descriptions for the drive, hydraulic, engine, auxiliary and ACD systems. Calibration procedures for the lift and tilt actuators and the hydrostatic pump are given in step-by-step form, as are the operator and service mode steering drift compensation procedures.

Cab, Mainframe and Operator Station

The mainframe section handles the structural and operator-side work: seat bar removal and compression spring assembly, operator cab gas springs and cab removal, operator and suspension seat service, seat belt replacement, hand lever and power Bob-Tach service including lever, wedge, pivot pin bushing and seal work, lift arm and stabilizer bar removal, rear grille, rear door and striker adjustment, fuel tank removal, control pedals and linkage adjustment, control panel and SJC control panel removal, control handle and joystick service, access panels, rear and side windows, cab door alignment and adjustment, armrest, lower panels, headliner and fan duct panels.

HVAC and Optional Equipment

For machines fitted with air conditioning, the HVAC chapters cover the refrigerant flow path, regular maintenance including fresh air and recirculation filters and the air conditioning belt, troubleshooting by symptom and by gauge pressure, evacuation and recharging, compressor service and oil check, condenser, receiver/drier and pressure switch, evaporator/heater unit, thermostat, expansion valve, evaporator coil, heater coil, blower fan and heater valve. Optional equipment covered elsewhere in the manual includes the two-speed drive, high flow hydraulics, automatic ride control, bucket positioning, reversing fan, rear auxiliary diverter valve and Power Bob-Tach.

Why the Bobcat S590 Skid-Steer Loader Service Manual Matters

Skid-steer loaders are compact, heavily loaded machines, and the S590 is no exception. Torque values that are guessed, seal orientations that are reversed, charge pressures that are set by feel and hydrostatic neutral adjustments that are skipped all show up later as failed pumps, drifting travel and premature component wear. Having the correct procedure, the correct specification and the correct sequence in front of you removes that guesswork. The manual also carries the diagnostic service code list, which turns an instrument panel warning into a defined starting point instead of a search, and the wiring schematics, which make tracing an intermittent electrical fault a matter of following a circuit rather than pulling the harness apart.

Get the Bobcat S590 Service Manual Delivered Instantly

With the Bobcat S590 Skid-Steer Loader Service Manual on hand you can service the engine and emissions system, rebuild lift and tilt cylinders, test and adjust the hydraulic pump, service the hydrostatic pump and motors, replace drive chains and axle bearings, diagnose controller and sensor faults, calibrate the lift, tilt and hydrostatic systems, and maintain the HVAC package. Correct procedures and correct specifications are what separate a repair that lasts from one that comes back. The file is delivered as an instant PDF download after payment, with no shipping and no waiting, and it can be read on a laptop, tablet or phone in the workshop or printed for the bench.