Bobcat S590 Skid-Steer Loader Service Manual SN B4RF11001 & Above – PDF DOWNLOAD

Description

Bobcat S590 Skid-Steer Loader Service Manual SN B4RF11001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat S590 Skid-Steer Loader Service Manual SN B4RF11001 & Above – PDF DOWNLOAD

Language : English
Pages : 1026
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S590 Skid-Steer Loader Service Manual SN B4RF11001 & Above – PDF DOWNLOAD

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:

TABLE OF CONTENTS:

Bobcat S590 Skid-Steer Loader Service Manual SN B4RF11001 & Above – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
LOADER IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 23
Procedure 23
LIFT ARM SUPPORT 25
Description 25
Installing 26
Removing 27
OPERATOR CAB 29
Description 29
Cab Door Sensor 29
Raising 30
Lowering 31
Special Applications Kit 32
Special Applications Kit Inspection And Maintenance 32
Forestry Door And Window Kit 33
Forestry Door And Window Kit Inspection And Maintenance 33
TRANSPORTING THE LOADER ON A TRAILER 35
Loading And Unloading 35
Fastening 35
TOWING THE LOADER 37
Procedure 37
REMOTE START TOOL KIT – MEL1563 39
Remote Start Tool – MEL1563 39
Service Tool Harness Communicator – MEL1566 41
Remote Start Procedure 41
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 45
Description 45
Remote Start Tool (Service Tool) – 7022042 46
Loader Service Tool Harness – 6689747 47
Computer Service Tool Harness – 6689746 48
Remote Start Procedure 49
SERVICE SCHEDULE 53
Maintenance Intervals 53
ENGINE AIR CLEANER 55
Replacing Filters 55
ENGINE COOLING SYSTEM 57
Maintenance Platform 57
Cleaning 57
Checking And Adding Coolant 60
Removing And Replacing Coolant 61
FUEL SYSTEM 63
Fuel Specifications 63
Biodiesel Blend Fuel 63
Filling The Fuel Tank 64
Removing Water From Main Fuel Filter 65
Replacing Fuel Pre-Filter 66
Replacing Main Fuel Filter 67
ENGINE LUBRICATION SYSTEM 69
Checking And Adding Engine Oil 69
Engine Oil Chart 69
Removing And Replacing Oil And Filter 70
HYDRAULIC / HYDROSTATIC SYSTEM 73
Checking And Adding Fluid 73
Hydraulic / Hydrostatic Fluid Chart 73
Removing And Replacing Hydraulic Fluid 74
Removing And Replacing Hydraulic / Hydrostatic Filter 76
Removing And Replacing Hydraulic Charge Filter 77
Replacing Reservoir Breather Cap 78
FINAL DRIVE TRANSMISSION (CHAINCASE) 79
Checking And Adding Fluid 79
Removing And Replacing Fluid 79
BOB-TACH (HAND LEVER) 81
Inspection And Maintenance 81
BOB-TACH (POWER) 83
Inspection And Maintenance 83
LUBRICATING THE LOADER 85
Lubrication Locations 85
TIRE MAINTENANCE 89
Wheel Nuts 89
Rotating 89
Mounting 90
PIVOT PINS 91
Inspection And Maintenance 91
LOADER STORAGE AND RETURN TO SERVICE 93
Storage 93
Return To Service 93
STOPPING THE ENGINE AND LEAVING THE LOADER 95
Procedure 95
EMERGENCY EXIT 97
Rear Window Identification 97
Rear Window Removal (Latches) 97
Rear Window Removal (Rubber Cord) 97
External Access (Rear Window With Latches) 98
External Access (Rear Window With Rubber Cord) 98
Front Door 99
SEAT BELT 101
Inspection And Maintenance 101
HYDRAULIC SYSTEM 103
HYDRAULIC / HYDROSTATIC SCHEMATICS 107
HYDRAULIC SYSTEM INFORMATION 115
Glossary Of Hydraulic / Hydrostatic Symbols 115
Troubleshooting 119
CYLINDER (LIFT) 121
Testing 121
Removal And Installation 122
Parts Identification 126
Disassembly 127
Assembly 129
CYLINDER (TILT) 133
Testing 133
Removal And Installation 134
Base End Pivot Pin Removal And Installation 135
Parts Identification 136
Disassembly 137
Assembly 139
CYLINDER (BOB-TACH) 143
Testing 143
Removal And Installation 144
Parts Identification 145
Disassembly 146
Assembly 148
MAIN RELIEF VALVE 151
Description 151
Testing 152
Adjusting 154
Removal And Installation 155
HYDRAULIC CONTROL VALVE (STANDARD) 157
Description 157
Removal And Installation 158
Mount Bracket Removal And Installation 161
Identification Chart 162
Lift Load Check Valve Removal And Installation 163
Load Check Valve Removal And Installation (Tilt And Auxiliary) 164
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 165
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 165
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 166
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 166
Port Relief Valve Removal And Installation 167
Plug Removal And Installation 169
Rubber Boot Removal And Installation 170
End Cap Block Removal And Installation 170
Lift Spool And Detent Removal And Installation 171
Tilt Spool Removal And Installation 179
Auxiliary Spool Removal And Installation 181
Auxiliary Solenoid Removal And Installation 182
Solenoid Removal And Installation 183
Lock Valve Removal And Installation 184
Lift Arm Bypass Orifice Removal And Installation 186
Main Relief Valve Removal And Installation 186
Check Valve Removal And Installation 187
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 189
Description 189
Removal And Installation 189
Mount Bracket Removal And Installation 192
Actuator Removal And Installation (In Loader) 193
Actuator Removal And Installation (Out Of Loader) 195
Identification Chart 198
Mount Bracket Removal And Installation 199
Lift Load Check Valve Removal And Installation 199
Load Check Valve Removal And Installation (Tilt And Auxiliary) 200
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 201
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 201
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 202
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 202
Port Relief Valve Removal And Installation 203
Plug Removal And Installation 205
End Cap Block Removal And Installation 206
Lift Spool Removal And Installation 206
Lift Spool Disassembly And Assembly 208
Tilt Spool Removal And Installation 209
Auxiliary Spool Removal And Installation 211
Auxiliary Solenoid Removal And Installation 212
Solenoid Removal And Installation 213
Lock Valve Removal And Installation 214
Lift Arm Bypass Orifice Removal And Installation 216
Main Relief Valve Removal And Installation 216
Check Valve Removal And Installation 217
LIFT ARM BYPASS CONTROL VALVE 219
Description 219
Testing 219
Removal And Installation 220
Bracket Removal And Installation 221
Disassembly And Assembly 221
HYDRAULIC PUMP 223
Description 223
Pump Test At Quick Couplers 224
Direct Pump Test (Standard Section) 226
Direct Pump Test (Charge Section) 228
Removal And Installation 230
Hydraulic Pump Startup 232
Parts Identification 233
Disassembly And Assembly 234
HYDRAULIC PUMP (HIGH FLOW) 235
Description 235
Pump Test At Quick Couplers 236
Direct Pump Test (Standard Section) 238
Direct Pump Test (Charge Section) 239
Direct Pump Test (High Flow Section) 241
High Flow Relief Valve Adjustment 243
High Flow Relief Valve Removal And Installation 245
Solenoid Removal And Installation 246
Removal And Installation 247
Hydraulic Pump Startup 249
Parts Identification 250
Disassembly And Assembly 251
HYDRAULIC / HYDROSTATIC FILTERS 253
Description 253
Housing Removal And Installation 253
HYDRAULIC FLUID RESERVOIR 255
Description 255
Removal And Installation 255
Hydraulic Fluid Screen 256
OIL COOLER 257
Removal And Installation 257
BUCKET POSITION VALVE 259
Description 259
Solenoid Removal And Installation 259
Solenoid Testing 261
Removal And Installation 261
Disassembly And Assembly 263
REAR AUXILIARY DIVERTER VALVE 265
Description 265
Solenoid Testing 265
Removal And Installation 266
Disassembly And Assembly 267
BOB-TACH (POWER) BLOCK 273
Description 273
Testing Relief Valve 274
Removal And Installation 276
Disassembly And Assembly 278
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 283
Description 283
Removal And Installation 284
Disassembly And Assembly (FFI/FI) 284
Disassembly And Assembly (FFH/FH) 286
AUTOMATIC RIDE CONTROL 289
Description 289
Removal And Installation 290
Checking The Pressure In The Accumulator 292
Adding Nitrogen To The Accumulator 294
HYDROSTATIC SYSTEM 297
HYDROSTATIC SYSTEM INFORMATION 299
Description 299
Troubleshooting 300
HYDROSTATIC DRIVE MOTOR 301
Description 301
Removal And Installation 301
Parts Identification 304
Disassembly And Assembly 305
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 311
Description 311
Removal And Installation (Left Side) 312
Removal And Installation (Right Side) 315
Parts Identification 318
Disassembly 319
Assembly 332
HYDROSTATIC MOTOR CARRIER 347
Description 347
Shaft Seal Removal And Installation 348
Removal And Installation 350
Parts Identification 352
Disassembly 353
Assembly 355
HYDROSTATIC MOTOR CARRIER (TWO-SPEED) 359
Description 359
Shaft Seal Removal And Installation 360
Removal And Installation 362
Parts Identification 364
Disassembly 365
Assembly 367
CHARGE PRESSURE 371
Description 371
Testing 372
Adjusting 374
Sender Removal And Installation 376
HYDROSTATIC PUMP 377
Description 377
Removal And Installation 378
Hydrostatic Pump Startup 379
Replenishing / High Pressure Relief Valve Removal And Installation 380
Parts Identification (Left Half) 381
Parts Identification (Right Half) 382
Disassembly 383
Assembly 390
HYDROSTATIC PUMP (SJC) 397
Description 397
Port Locations And Gauge Installation 398
Removal And Installation 399
Hydrostatic Pump Startup 401
Parts Identification 402
High Pressure Relief And Bypass Valve 405
Charge Pressure Relief Valve 406
Disassembly And Assembly 407
Mechanical Neutral Adjustment 419
Hydraulic Controller Neutral Adjustment 421
DRIVE BELT 423
Belt Adjustment 423
Stop Adjustment 423
Belt Replacement 424
Tensioner Pulley Removal And Installation 426
Tensioner Pulley Disassembly And Assembly 426
TWO-SPEED 429
Valve Block Removal And Installation 429
Valve Block Disassembly And Assembly 430
DRAIN MANIFOLD 431
Description 431
Drain Manifold Removal And Installation 431
DRIVE SYSTEM 433
BRAKE 435
Description 435
Disc Removal And Installation 435
DRIVE COMPONENTS 437
Description 437
Axle Seal Removal And Installation 438
Axle, Sprocket And Bearings Removal And Installation 440
Chain Removal And Installation 445
CHAINCASE 447
Description 447
Front Cover Removal And Installation 447
Center Cover Removal And Installation 448
Rear Cover Removal And Installation 449
MAINFRAME 451
SEAT BAR 455
Description 455
Removal And Installation 455
Disassembly And Assembly 456
Compression Spring Disassembly And Assembly 457
OPERATOR CAB 459
Gas Spring Removal And Installation 459
Gas Spring Bracket Disassembly And Assembly 460
Removal And Installation 460
OPERATOR SEAT 463
Removal And Installation 463
Seat Belt Removal And Installation (Retractable) 463
Seat Belt And Bracket Removal And Installation (Standard) 464
Seat Belt Bracket Removal And Installation 464
OPERATOR SEAT (SUSPENSION) 465
Removal And Installation 465
Slide Rail Removal And Installation 465
Seat Belt Removal And Installation 466
Lower Cushion Removal 466
Lower Cushion Installation 467
Back Cushion Removal And Installation 467
Shock Removal And Installation 468
3-Point Seat Belt Removal And Installation 468
BOB-TACH (HAND LEVER) 471
Description 471
Removal And Installation 471
Lever And Wedge Disassembly And Assembly 474
Pivot Pin Bushing And Seal Removal And Installation 476
BOB-TACH (POWER) 477
Description 477
Removal And Installation 477
Lever And Wedge Disassembly And Assembly 480
Pivot Pin Bushing And Seal Removal And Installation 482
LIFT ARMS 483
Stabilizer Bar Removal And Installation 483
Link Removal And Installation 484
Removal And Installation 485
REAR GRILLE 489
Removing 489
Installing 489
Shield Removal And Installation 490
REAR DOOR (TAILGATE) 491
Removal And Installation 491
Striker Removal And Installation 492
Striker Disassembly And Assembly 492
Striker Adjusting 493
Latch Removal And Installation 494
FUEL TANK 495
Removal And Installation 495
Fuel Level Sender Removal And Installation 497
Fuel Fill Screen Removal And Installation 497
CONTROL PEDALS AND LINKAGES 499
Description 499
Pedal Removal And Installation 499
Linkage Removal And Installation 500
Pedal (Adjusting) 501
Floor Pan Removal And Installation 502
CONTROL PEDALS AND LINKAGES (ACS) 503
Description 503
Pedal Removal And Installation 503
Linkage Removal And Installation 504
Pedal (Adjusting) 504
Floor Pan Removal And Installation 505
CONTROL PANEL 507
Description 507
Removal And Installation 508
Disassembly And Assembly 510
Linkage Removal And Installation 512
Pintle Arm Disassembly And Assembly 515
Linkage Neutral (Adjusting) 516
Linkage Travel (Adjusting) 520
Shock Removal And Installation 524
CONTROL PANEL (SJC) 525
Description 525
Removal And Installation 525
CONTROL HANDLE / LEVER 527
Description 527
Lever Removal And Installation 527
Boot Removal And Installation 528
CONTROL HANDLE / LEVER (ACS) 529
Description 529
Handle Sensor Removal And Installation 529
Handle Removal And Installation 532
Handle Disassembly And Assembly 533
Lever Removal And Installation 533
Boot Removal And Installation 534
CONTROL HANDLE / LEVER (SJC) 535
Description 535
Joystick Testing 535
Joystick Removal And Installation 536
ACCESS PANEL (INSIDE) 537
Removal And Installation (Left) 537
Removal And Installation (Right) 537
ACCESS PANEL (INSIDE) (SJC) 539
Removal And Installation (Left) 539
Removal And Installation (Right) 539
WINDOW (REAR) 541
Rear Window Identification 541
Rear Window Removal (Latches) 541
Rear Window Removal (Rubber Cord) 541
External Access (Rear Window With Latches) 542
External Access (Rear Window With Rubber Cord) 542
Disassembly And Assembly (Latches) 543
WINDOW (TOP) 545
Removal And Installation 545
WINDOW (SIDE) 547
Removal And Installation 547
CAB DOOR 549
Description 549
Removal And Installation 549
Disassembly And Assembly 550
Aligning 551
Adjusting 552
Checking Operation 552
ARMREST 553
Description 553
Removal And Installation 554
Disassembly And Assembly 555
LEFT SIDE LOWER PANEL 557
Removal And Installation 557
Disassembly And Assembly 560
RIGHT SIDE LOWER PANEL 561
Removal And Installation 561
Disassembly And Assembly 563
HEADLINER 565
Removal And Installation 565
FAN DUCT PANELS 567
Removal And Installation 567
ELECTRICAL SYSTEM 569
ELECTRICAL SCHEMATICS 575
ELECTRICAL SYSTEM INFORMATION 617
Glossary Of Electrical Symbols 617
Standard Cab Harness Connectors 620
Deluxe Cab Harness Connectors 621
Mainframe Harness Connectors – Manual Controls 622
Mainframe Harness Connectors – SJC 623
Engine Harness Connectors 624
Description 625
Troubleshooting 626
Fuse And Relay Location / Identification 627
Solenoid Testing 632
BATTERY 633
Removal And Installation 633
Battery Maintenance 634
Maintaining Battery Charge Level 634
Battery Service During Machine Storage 634
Battery Testing 635
Battery Charging 635
Using A Booster Battery (Jump Starting) 636
ALTERNATOR 637
Belt Adjustment 637
Belt Replacement 638
Charging System Inspection 639
Alternator Voltage Testing 640
Low Voltage Testing 640
High Voltage Testing 641
Removal And Installation 642
Parts Identification 644
STARTER 645
Testing 645
Removal And Installation 645
Parts Identification 646
INSTRUMENT PANELS 647
Left Panel 647
Display Screen 649
Right Panel (Standard Key Panel) 650
Right Panel (Keyless Start Panel) 651
Right Panel (Deluxe Instrumentation Panel) 652
Left Switch Panel 654
Right Switch Panel 654
Left Side Lower Panel 655
Right Side Lower Panel 655
Left Panel Removal And Installation 656
Right Panel (Standard Key Panel) Removal And Installation 656
Right Panel (Keyless Start Panel) Removal And Installation 657
Right Panel (Deluxe Instrumentation Panel) Removal And Installation 657
Key Switch Disassembly And Assembly 658
Alarm Disassembly And Assembly 658
Left Switch Panel Removal And Installation 659
Right Switch Panel Removal And Installation 659
LIGHTS 661
Front Removal And Installation 661
Rear Removal And Installation 662
Cab Light Removal And Installation 662
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) 663
Description 663
Connector Identification 664
Removal And Installation 670
BOBCAT CONTROLLER (ACS) 671
Description 671
Connector And Wire Identification 672
Removal And Installation 673
BOBCAT CONTROLLER (SJC) (DRIVE) 675
Description 675
Connector Identification 676
Removal And Installation 678
ENGINE CONTROL UNIT (ECU) 679
Description 679
Cleaning 680
Removal And Installation 681
DIAGNOSTIC SERVICE CODES 683
Viewing Service Codes 683
Service Codes List 684
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 693
Description 693
Inspecting The BICS™ (Engine STOPPED – Key ON) 694
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 694
Inspecting The Seat Bar Sensor (Engine RUNNING) 694
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 694
Inspecting The Lift Arm Bypass Control 694
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 694
Troubleshooting 695
SEAT BAR SENSOR 697
Description 697
Troubleshooting 697
Testing 698
Removal 699
Installation 701
Bobcat Interlock Control System (BICS™) Circuit Test 702
TRACTION LOCK 705
Description 705
Troubleshooting 706
Inspecting 707
CONTROL SYSTEM (ACS) 709
Description 709
Troubleshooting 710
Handle Sensor Connector Disassembly And Assembly 711
Switch Handle Removal 712
Switch Handle Installation 714
Actuator Connector Disassembly And Assembly 717
Handle Lock Solenoid Removal And Installation 718
Handle Lock Solenoid Disassembly And Assembly 718
Foot Sensor Removal And Installation 719
Foot Sensor Disassembly And Assembly 720
Foot Sensor Lock Solenoid Removal And Installation 720
ELECTRICAL / HYDRAULIC CONTROLS 721
Identification Chart 721
Description 722
Identification Chart ACD Group 0 723
Identification Chart ACD Group 1 724
Identification Chart ACD Group 2 725
Identification Chart ACD Group 3 726
ELECTRICAL / HYDRAULIC CONTROLS (ACS) 727
Identification Chart 727
Description 728
Identification Chart ACD Group 0 729
Identification Chart ACD Group 1 730
Identification Chart ACD Group 2 731
Identification Chart ACD Group 3 732
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 733
Identification Chart 733
Description 734
Identification Chart ACD Group 0 735
Identification Chart ACD Group 1 736
Identification Chart ACD Group 2 737
Identification Chart ACD Group 3 738
SERVICE PC (LAPTOP COMPUTER) 739
Connecting Remote Start Tool 739
Connecting Remote Start Tool (Service Tool) 739
CALIBRATION 741
Description 741
Actuator Testing 741
Lift And Tilt Calibration (SJC) 744
Hydrostatic Pump Calibration (SJC) 746
Lift And Tilt Calibration (ACS) 751
STEERING DRIFT COMPENSATION (OPERATOR MODE) 753
Description 753
Operation 753
STEERING DRIFT COMPENSATION (SERVICE MODE) 755
Description 755
Operation 755
CONTROL PANEL SETUP 757
Right Panel Setup (Deluxe Instrumentation Panel) 757
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 761
Password Description 761
Changing The Owner Password 761
Changing The User Passwords 762
Password Lockout Feature 762
PASSWORD SETUP (KEYLESS START PANEL) 763
Password Description 763
Changing The Owner Password 763
Password Lockout Feature 763
MAINTENANCE CLOCK 765
Description 765
Setup 766
Reset 769
BACK-UP ALARM SYSTEM 771
Description 771
Inspecting 771
Adjusting Switch Position 772
Troubleshooting (Standard And ACS) 773
Troubleshooting (Joystick) 774
Alarm Removal And Installation 775
Switch Removal And Installation 775
FRONT HORN 777
Removal And Installation 777
Troubleshooting 778
Troubleshooting (Joystick) 779
ENGINE SPEED CONTROL (HAND) 781
Removal And Installation 781
ENGINE SPEED CONTROL (FOOT) 783
Removal And Installation 783
Disassembly And Assembly 784
Foot Throttle Calibration 786
CAMSHAFT AND CRANKSHAFT POSITION SENSOR 789
Removal And Installation 789
MACHINE IQ 791
Description 791
Removal And Installation 791
Procedure 792
ENGINE SERVICE 793
ENGINE INFORMATION 797
Description 797
Specifications 798
Sensor Location 800
Torque Values 805
Troubleshooting 807
Engine Removal And Installation 809
Engine Mount Replacement 817
Compression – Testing 819
Injector Signal – Testing 821
Injector Signal – Testing (In-Line) 823
Oil Pressure Testing (At Oil Sensor On Block) 825
Oil Pressure Testing (At Turbocharger Oil Inlet) 827
DIESEL OXIDATION CATALYST (DOC) 829
Removal And Installation 829
AIR CLEANER 831
Housing Removal And Installation 831
ENGINE COOLING SYSTEM 833
Radiator / Oil Cooler Removal And Installation 833
Hydraulic Fan Description 836
Reversible Hydraulic Fan Description 836
Fan Duct Removal And Installation 836
Hydraulic Fan Motor Assembly Removal And Installation 837
Hydraulic Fan Motor Removal And Installation 838
Hydraulic Fan Motor Disassembly And Assembly 840
Blower Housing Removal And Installation 848
Water Pump Removal And Installation 849
Thermostat Housing Removal And Installation 850
Testing The Thermostat 851
LUBRICATION SYSTEM 853
Description 853
Oil Pan Removal And Installation 854
Oil Pump Removal And Installation 855
Oil Pump Relief Valve Description 856
Oil Pump Relief Valve Removal And Installation 856
Oil Cooler Removal And Installation 857
Oil Filter Head Removal And Installation 858
Oil Cooler Bypass Description 859
Oil Cooler Bypass Removal And Installation 859
FUEL SYSTEM 861
Description 861
Fuel Filter Housing Removal And Installation 862
Fuel Lift Pump Removal And Installation 864
Transfer Pump / High Pressure Pump Removal And Installation 864
Fuel Temperature Sensor Removal And Installation 866
Fuel Cooler Removal And Installation 867
Fuel Recirculation Valve (FRV) Removal And Installation 867
Fuel Injector Removal And Installation 868
Injector Coding 870
CYLINDER HEAD 871
Glow Plugs Testing 871
Glow Plug Removal And Installation 872
Valve Clearance Adjustment 873
Cylinder Head Removal And Installation 875
Cylinder Head Disassembly And Assembly 879
Cylinder Head Inspection 880
Cylinder Head Top Clearance 881
Valve Step Height 882
Valve Stem Height 882
Valve Guide 883
Valve 883
Valve Spring 884
Rocker Arm Shaft Disassembly And Assembly 885
Rocker Arm Shaft Inspection 886
Push Rod Inspection 886
CRANKSHAFT AND PISTONS 887
Piston And Connecting Rod Removal And Installation 887
Piston And Connecting Rod Inspection 888
Crankshaft Removal And Installation 890
Cylinder Block Inspection 893
Crankshaft Inspection 895
Connecting Rod Inspection 895
Engine Component Class 896
CAMSHAFT 899
Removal And Installation 899
Inspecting 900
GEARCASE 903
Gearcase Cover Removal And Installation 903
Gear Backlash 904
Gear Timing 905
Idle Gear Removal And Installation 906
Idle Gear Inspection 906
TURBOCHARGER 907
Description 907
Removal And Installation 907
Inspection 909
FLYWHEEL AND HOUSING 911
Flywheel Removal And Installation 911
Ring Gear Removal And Installation 912
Housing Removal And Installation 912
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 913
Description 913
Removal And Installation 914
Disassembly And Assembly 918
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 921
AIR CONDITIONING SYSTEM FLOW 923
Description 923
Chart 924
Components 925
Safety Equipment 928
REGULAR MAINTENANCE 929
Filters 929
Belt Adjustment 930
Belt Replacement 930
Air Conditioning Condenser 930
Air Conditioning Lubrication 930
Air Conditioning Service Chart 931
Evaporator / Heater Coil 932
TROUBLESHOOTING 935
Blower Motor Does Not Operate 935
Blower Motor Operates Normally, But Air Flow Is Insufficient 935
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 935
The Compressor Does Not Operate At All, Or Operates Improperly 935
Gauge Pressure Related Troubleshooting 936
Troubleshooting Tree 938
Temperature / Pressure Chart 942
Poor A/C Performance 944
HVAC Repair And Leaks 945
Electrical System 946
Engine Coolant Bypassing The Heater Valve 952
Heater Valve Not Opening Or Closing 953
SYSTEM CHARGING AND RECLAMATION 955
Refrigerant Identification 955
Reclamation And Charging With Recovery / Charging Unit 956
COMPRESSOR 959
Removal And Installation 959
Oil 961
Oil Check 962
CONDENSER 965
Removal And Installation 965
RECEIVER / DRIER 967
Receiver / Drier Removal And Installation 967
Pressure Switch Removal And Installation 969
Schrader® Valve Removal And Installation 970
EVAPORATOR / HEATER UNIT 971
Removal And Installation 971
THERMOSTAT 973
Description 973
Removal And Installation 974
EXPANSION VALVE 975
Removal And Installation 975
EVAPORATOR COIL 977
Removal And Installation 977
HEATER COIL 979
Removal And Installation 979
BLOWER FAN 981
Removal And Installation 981
Disassembly And Assembly 981
HEATER VALVE 985
Removal And Installation 985
EVAPORATOR / HEATER COVER 987
Removing 987
Installing 987
SPECIFICATIONS 989
(S590) LOADER SPECIFICATIONS 991
Machine Dimensions 991
Performance 992
Engine 992
Drive System 993
Controls 993
Hydraulic System 994
Electrical System 995
Capacities 995
Tires 996
TECHINCAL SERVICE GUIDE SPECIFICATIONS 997
Engine 997
Engine Torques 997
Cooling System 997
Loader Torques 998
Hydraulic / Hydrostatic System 998
Fuel Consumption 998
TORQUE SPECIFICATIONS FOR BOLTS 999
Torque For General SAE Bolts 999
Torque For General Metric Bolts 1000
HYDRAULIC CONNECTION SPECIFICATIONS 1001
Straight Thread O-ring Fitting 1001
Flare Fitting 1002
Tubelines And Hoses 1002
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 1003
Specifications 1003
CONVERSIONS 1005
Decimal And Millimeter Equivalent Chart 1005
U S To Metric Conversion Chart 1005
SERVICE TOOLS REQUIRED 1007
Remote Start Tools 1007
Hydraulic Tools 1008
Mainframe And Drive Tools 1011
Electrical Tools 1014
Engine Tools 1015
HVAC Tools 1020
ALPHABETICAL INDEX 1021

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