Bobcat T590 Compact Track Loader Service Manual 6989683 – PDF DOWNLOAD
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Bobcat T590 Compact Track Loader Service Manual 6989683 – PDF DOWNLOAD
S/N A3NR11001 & Above
S/N A3NS11001 & Above
S/N B3ZA11001 & Above
Description
Bobcat T590 Compact Track Loader Service Manual 6989683 – PDF DOWNLOAD
FILE DETAILS:
Bobcat T590 Compact Track Loader Service Manual 6989683 – PDF DOWNLOAD
Language : English
Pages : 1296
Downloadable : Yes
File Type : PDF
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DESCRIPTION:
Bobcat T590 Compact Track Loader Service Manual 6989683 – PDF DOWNLOAD
S/N A3NR11001 & Above
S/N A3NS11001 & Above
S/N B3ZA11001 & Above
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 T590 Compact Track Loader Service Manual 6989683 – 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 DEVICE..................................................................................... 25 Description............................................................................................. 25 Installing.............................................................................................. 26 Removing................................................................................................ 27 OPERATOR CAB................................................................................................ 29 Description............................................................................................. 29 Raising................................................................................................. 29 Lowering................................................................................................ 30 Cab Door Sensor......................................................................................... 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 Cooling System Identification........................................................................... 57 Cleaning (Earlier Models)............................................................................... 58 Cleaning (Later Models)................................................................................. 60 Checking And Adding Coolant............................................................................. 62 Removing And Replacing Coolant.......................................................................... 63 FUEL SYSTEM................................................................................................. 65 Fuel Specifications..................................................................................... 65 Biodiesel Blend Fuel.................................................................................... 65 Filling The Fuel Tank................................................................................... 66 Fuel Filter............................................................................................. 67 Removing Air From The Fuel System....................................................................... 68 ENGINE LUBRICATION SYSTEM................................................................................... 69 Checking And Adding Engine Oil.......................................................................... 69 Engine Oil Chart........................................................................................ 69 Removing And Replacing Oil And Filter................................................................... 70 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................................. 71 Checking And Adding Fluid............................................................................... 71 Hydraulic / Hydrostatic Fluid Chart..................................................................... 71 Removing And Replacing Hydraulic Fluid.................................................................. 72 Removing And Replacing Hydraulic / Hydrostatic Filter................................................... 74 Removing And Replacing Hydraulic Charge Filter.......................................................... 75 Replacing Reservoir Breather Cap........................................................................ 77 BOB-TACH (HAND LEVER)....................................................................................... 79 Inspection And Maintenance.............................................................................. 79 BOB-TACH (POWER)............................................................................................ 81 Inspection And Maintenance.............................................................................. 81 LUBRICATING THE LOADER...................................................................................... 83 Lubrication Locations................................................................................... 83 Track Roller And Idler Lubrication...................................................................... 86 SPARK ARRESTER MUFFLER...................................................................................... 87 Cleaning Procedure...................................................................................... 87 PIVOT PINS.................................................................................................. 89 Inspection And Maintenance.............................................................................. 89 LOADER STORAGE AND RETURN TO SERVICE........................................................................ 91 Storage................................................................................................. 91 Return To Service....................................................................................... 91 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................................. 93 Procedure............................................................................................... 93 EMERGENCY EXIT.............................................................................................. 95 Rear Window Identification.............................................................................. 95 Rear Window Removal (Latches)........................................................................... 95 Rear Window Removal (Rubber Cord)....................................................................... 96 External Access (Rear Window With Latches).............................................................. 96 External Access (Rear Window With Rubber Cord).......................................................... 97 Front Door.............................................................................................. 97 SEAT BELT................................................................................................... 99 Inspection And Maintenance.............................................................................. 99 HYDRAULIC SYSTEM................................................................................................ 101 HYDRAULIC/HYDROSTATIC SCHEMATIC............................................................................. 107 HYDRAULIC SYSTEM INFORMATION................................................................................ 127 Glossary Of Hydraulic / Hydrostatic Symbols............................................................. 127 Troubleshooting......................................................................................... 131 CYLINDER (LIFT)............................................................................................. 133 Testing................................................................................................. 133 Removal And Installation................................................................................ 134 Parts Identification.................................................................................... 138 Disassembly............................................................................................. 139 Assembly................................................................................................ 141 CYLINDER (TILT)............................................................................................. 145 Testing................................................................................................. 145 Removal And Installation................................................................................ 146 Base End Pivot Pin Removal And Installation............................................................. 147 Parts Identification.................................................................................... 148 Disassembly............................................................................................. 149 Assembly................................................................................................ 151 CYLINDER (LIFT) (S/N B3ZA11090 & ABOVE)..................................................................... 155 Testing................................................................................................. 155 Removal And Installation................................................................................ 156 Parts Identification.................................................................................... 160 Disassembly............................................................................................. 161 Assembly................................................................................................ 163 CYLINDER (TILT) (S/N B3ZA11090 & ABOVE)..................................................................... 167 Testing................................................................................................. 167 Removal And Installation................................................................................ 168 Base End Pivot Pin Removal And Installation............................................................. 169 Parts Identification.................................................................................... 170 Disassembly............................................................................................. 171 Assembly................................................................................................ 173 CYLINDER (BOB-TACH)......................................................................................... 177 Testing................................................................................................. 177 Removal And Installation................................................................................ 178 Parts Identification.................................................................................... 179 Disassembly............................................................................................. 180 Assembly................................................................................................ 182 MAIN RELIEF VALVE........................................................................................... 185 Description............................................................................................. 185 Testing................................................................................................. 186 Adjusting............................................................................................... 188 Removal And Installation................................................................................ 189 HYDRAULIC CONTROL VALVE (STANDARD).......................................................................... 191 Description............................................................................................. 191 Removal And Installation................................................................................ 192 Mount Bracket Removal And Installation.................................................................. 195 Identification Chart.................................................................................... 196 Lift Load Check Valve Removal And Installation.......................................................... 197 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................................... 198 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................................... 199 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........................... 199 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........................... 200 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............................ 200 Port Relief Valve Removal And Installation.............................................................. 201 Plug Removal And Installation........................................................................... 203 Rubber Boot Removal And Installation.................................................................... 204 End Cap Block Removal And Installation.................................................................. 204 Lift Spool And Detent Removal And Installation.......................................................... 205 Tilt Spool Removal And Installation..................................................................... 213 Auxiliary Spool Removal And Installation................................................................ 215 Auxiliary Solenoid Removal And Installation............................................................. 216 Solenoid Removal And Installation....................................................................... 217 Lock Valve Removal And Installation..................................................................... 218 Lift Arm Bypass Orifice Removal And Installation........................................................ 220 Main Relief Valve Removal And Installation.............................................................. 220 Check Valve Removal And Installation.................................................................... 221 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)...................................................................... 223 Description............................................................................................. 223 Removal And Installation................................................................................ 223 Actuator Removal And Installation (In Loader)........................................................... 227 Actuator Removal And Installation (Out Of Loader)....................................................... 229 Identification Chart.................................................................................... 232 Mount Bracket Removal And Installation.................................................................. 233 Lift Load Check Valve Removal And Installation.......................................................... 233 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................................... 234 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................................... 235 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........................... 235 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........................... 236 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............................ 236 Port Relief Valve Removal And Installation.............................................................. 237 Plug Removal And Installation........................................................................... 239 End Cap Block Removal And Installation.................................................................. 240 Lift Spool Removal And Installation..................................................................... 240 Lift Spool Disassembly And Assembly..................................................................... 242 Tilt Spool Removal And Installation..................................................................... 243 Auxiliary Spool Removal And Installation................................................................ 245 Auxiliary Solenoid Removal And Installation............................................................. 246 Solenoid Removal And Installation....................................................................... 247 Lock Valve Removal And Installation..................................................................... 248 Lift Arm Bypass Orifice Removal And Installation........................................................ 250 Main Relief Valve Removal And Installation.............................................................. 250 Check Valve Removal And Installation.................................................................... 251 LIFT ARM BYPASS CONTROL VALVE............................................................................... 253 Description............................................................................................. 253 Testing................................................................................................. 253 Removal And Installation................................................................................ 254 Bracket Removal And Installation........................................................................ 255 Disassembly And Assembly................................................................................ 255 HYDRAULIC PUMP.............................................................................................. 257 Description............................................................................................. 257 Pump Test At Quick Couplers............................................................................. 258 Direct Pump Test (Standard Section)..................................................................... 260 Direct Pump Test (Charge Section)....................................................................... 262 Removal And Installation................................................................................ 264 Hydraulic Pump Startup.................................................................................. 266 Parts Identification.................................................................................... 267 Disassembly And Assembly................................................................................ 268 HYDRAULIC PUMP (HIGH FLOW).................................................................................. 269 Description............................................................................................. 269 Pump Test At Quick Couplers............................................................................. 270 Direct Pump Test (Standard Section)..................................................................... 272 Direct Pump Test (Charge Section)....................................................................... 273 Direct Pump Test (High Flow Section).................................................................... 275 High Flow Relief Valve Adjustment....................................................................... 277 High Flow Relief Valve Removal And Installation......................................................... 278 Solenoid Removal And Installation....................................................................... 279 Removal And Installation................................................................................ 280 Hydraulic Pump Startup.................................................................................. 282 Parts Identification.................................................................................... 283 Disassembly And Assembly................................................................................ 284 HYDRAULIC / HYDROSTATIC FILTERS............................................................................. 285 Description............................................................................................. 285 Housing Removal And Installation........................................................................ 285 HYDRAULIC FLUID RESERVOIR................................................................................... 287 Description............................................................................................. 287 Removal And Installation................................................................................ 287 Hydraulic Fluid Screen.................................................................................. 288 OIL COOLER (EARLIER MODELS)................................................................................. 289 Description............................................................................................. 289 Removal And Installation................................................................................ 289 OIL COOLER (LATER MODELS)................................................................................... 291 Removal And Installation................................................................................ 291 BUCKET POSITION VALVE....................................................................................... 293 Description............................................................................................. 293 Solenoid Removal And Installation....................................................................... 293 Solenoid Testing........................................................................................ 294 Removal And Installation................................................................................ 295 Disassembly And Assembly................................................................................ 297 REAR AUXILIARY DIVERTER VALVE............................................................................... 299 Description............................................................................................. 299 Solenoid Testing........................................................................................ 299 Removal And Installation................................................................................ 300 Disassembly And Assembly................................................................................ 301 BOB-TACH (POWER) BLOCK (S/N A3NR11001 - A3NR15033 AND S/N A3NS11001 - A3NS11685)............................ 307 Description............................................................................................. 307 Removal And Installation................................................................................ 307 Disassembly And Assembly................................................................................ 309 BOB-TACH (POWER) BLOCK (S/N A3NR15034, A3NS11686 & ABOVE)................................................... 317 Description............................................................................................. 317 Testing Relief Valve.................................................................................... 318 Removal And Installation................................................................................ 320 Disassembly And Assembly................................................................................ 322 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK..................................................................... 327 Description............................................................................................. 327 Removal And Installation................................................................................ 328 Disassembly And Assembly (FFI/FI)....................................................................... 328 Disassembly And Assembly (FFH/FH)....................................................................... 330 AUTOMATIC RIDE CONTROL...................................................................................... 333 Description............................................................................................. 333 Removal And Installation................................................................................ 334 Checking The Pressure In The Accumulator................................................................ 337 Adding Nitrogen To The Accumulator...................................................................... 339 HYDROSTATIC SYSTEM.............................................................................................. 341 HYDROSTATIC SYSTEM INFORMATION.............................................................................. 343 Description............................................................................................. 343 Troubleshooting......................................................................................... 344 HYDROSTATIC DRIVE MOTOR (S/N A3NR11001 - A3NR17189 AND S/N A3NS11001 - A3NS12025)........................... 345 Description............................................................................................. 345 Removing And Replacing Fluid............................................................................ 346 Removal And Installation................................................................................ 348 Parts Identification.................................................................................... 350 Disassembly............................................................................................. 352 Assembly................................................................................................ 360 HYDROSTATIC DRIVE MOTOR (S/N A3NR17190 AND A3NS12026 & ABOVE)............................................... 369 Description............................................................................................. 369 Removing And Replacing Fluid............................................................................ 370 Removal And Installation................................................................................ 371 Parts Identification (MCR5T)............................................................................ 373 Parts Identification (MCR6T) (Two-Speed)................................................................ 374 Disassembly And Assembly................................................................................ 375 CHARGE PRESSURE............................................................................................. 385 Description............................................................................................. 385 Testing................................................................................................. 386 Adjusting............................................................................................... 388 Sender Removal And Installation (Earlier Models)........................................................ 390 Sender Removal And Installation (Later Models).......................................................... 390 HYDROSTATIC PUMP............................................................................................ 391 Description............................................................................................. 391 Removal And Installation................................................................................ 392 Hydrostatic Pump Startup................................................................................ 393 Replenishing / High Pressure Relief Valve Removal And Installation...................................... 394 Parts Identification (Left Half)........................................................................ 395 Parts Identification (Right Half)....................................................................... 396 Disassembly............................................................................................. 397 Assembly................................................................................................ 404 HYDROSTATIC PUMP (SJC)...................................................................................... 411 Description............................................................................................. 411 Hydraulic Controller Removal And Installation........................................................... 412 Removal And Installation................................................................................ 414 Hydrostatic Pump Startup................................................................................ 416 Parts Identification.................................................................................... 417 High Pressure Relief And Bypass Valve................................................................... 418 Charge Relief Valve..................................................................................... 419 Disassembly And Assembly................................................................................ 420 Mechanical Neutral Adjustment........................................................................... 433 Hydraulic Controller Neutral Adjustment................................................................. 436 HYDROSTATIC PUMP (SJC) (S/N A3NR18254 & ABOVE).............................................................. 439 Description............................................................................................. 439 Port Locations And Gauge Installation................................................................... 440 Removal And Installation................................................................................ 441 Hydrostatic Pump Startup................................................................................ 443 Parts Identification.................................................................................... 444 High Pressure Relief And Bypass Valve................................................................... 447 Charge Pressure Relief Valve............................................................................ 448 Disassembly And Assembly................................................................................ 449 Mechanical Neutral Adjustment........................................................................... 460 Hydraulic Controller Neutral Adjustment................................................................. 462 DRIVE BELT.................................................................................................. 465 Belt Adjustment......................................................................................... 465 Belt Replacement........................................................................................ 466 DRAIN MANIFOLD.............................................................................................. 469 Description............................................................................................. 469 Drain Manifold Removal And Installation................................................................. 469 DRIVE SYSTEM.................................................................................................... 471 BRAKE....................................................................................................... 473 Description............................................................................................. 473 Block Removal And Installation.......................................................................... 474 Block Disassembly And Assembly.......................................................................... 476 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N A3NR11001 - A3NR16999 AND A3NS11001 - A3NS11999)........ 477 Description............................................................................................. 477 Checking Tension........................................................................................ 478 Adjusting Tension....................................................................................... 479 Track Removal And Installation.......................................................................... 480 Idler (Front) Removal And Installation.................................................................. 482 Track Tensioner Disassembly And Assembly................................................................ 485 Idler (Rear) Removal And Installation................................................................... 487 Roller Removal And Installation......................................................................... 487 Sprocket Removal And Installation....................................................................... 488 Track Housing Removal And Installation.................................................................. 489 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N A3NR11001 - A3NR16999 AND A3NS11001 - A3NS11999).... 491 Description............................................................................................. 491 Checking Tension........................................................................................ 492 Adjusting Tension....................................................................................... 493 Track Removal And Installation.......................................................................... 494 Idler (Front) Removal And Installation.................................................................. 496 Track Tensioner Disassembly And Assembly................................................................ 499 Idler (Rear) Removal And Installation................................................................... 501 Leaf Spring Removal And Installation.................................................................... 502 Sprocket Removal And Installation....................................................................... 503 Track Housing Removal And Installation.................................................................. 504 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N A3NR17001 AND A3NS12001 & ABOVE)........................ 507 Description............................................................................................. 507 Checking (Solid-Mounted Undercarriage).................................................................. 509 Adjusting (Solid-Mounted Undercarriage) (Earlier Models With Two Track Tension Fittings)................ 510 Adjusting (Solid-Mounted Undercarriage) (Later Models With One Track Tension Fitting)................... 511 Adjusting (Solid-Mounted Undercarriage) (Later Models With One Track Tension Fitting)................... 512 Track Removal And Installation.......................................................................... 513 Idler (Front) Removal And Installation.................................................................. 516 Track Tensioner Removal And Installation................................................................ 517 Track Tensioner Disassembly And Assembly................................................................ 518 Idler (Rear) Removal And Installation................................................................... 520 Roller Removal And Installation......................................................................... 520 Sprocket Removal And Installation (Twelve Sprocket Bolts)............................................... 521 Sprocket Removal And Installation (Fifteen Sprocket Bolts).............................................. 521 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N A3NR17001 AND A3NS12001 & ABOVE).................... 523 Description............................................................................................. 523 Checking (Roller Suspension Undercarriage).............................................................. 525 Adjusting (Roller Suspension Undercarriage) (Earlier Models With Two Track Tension Fittings)............ 526 Adjusting (Roller Suspension Undercarriage) (Later Models With One Track Tension Fitting)............... 527 Adjusting (Roller Suspension Undercarriage) (Later Models With One Track Tension Fitting)............... 528 Track Removal And Installation.......................................................................... 529 Idler (Front) Removal And Installation.................................................................. 532 Track Tensioner Removal And Installation................................................................ 533 Track Tensioner Disassembly And Assembly................................................................ 534 Idler (Rear) Removal And Installation................................................................... 536 Roller Removal And Installation......................................................................... 536 Leaf Spring Removal And Installation.................................................................... 537 Sprocket Removal And Installation (Twelve Sprocket Bolts)............................................... 538 Sprocket Removal And Installation (Fifteen Sprocket Bolts).............................................. 538 TRACK MAINTENANCE........................................................................................... 539 Track Damage Identification............................................................................. 539 MAINFRAME....................................................................................................... 551 SEAT BAR.................................................................................................... 555 Description............................................................................................. 555 Removal And Installation................................................................................ 555 Disassembly And Assembly................................................................................ 556 Compression Spring Disassembly And Assembly............................................................. 557 OPERATOR CAB................................................................................................ 559 Gas Spring Removal And Installation..................................................................... 559 Gas Spring Bracket Disassembly And Assembly............................................................. 560 Removal And Installation................................................................................ 560 OPERATOR SEAT (SUSPENSION).................................................................................. 563 Removal And Installation................................................................................ 563 Slide Rail Removal And Installation..................................................................... 563 Seat Belt Removal And Installation...................................................................... 564 Lower Cushion Removal................................................................................... 564 Lower Cushion Installation.............................................................................. 565 Back Cushion Removal And Installation................................................................... 565 Shock Removal And Installation.......................................................................... 566 3-Point Seat Belt Removal And Installation.............................................................. 566 BOB-TACH (HAND LEVER)....................................................................................... 569 Description............................................................................................. 569 Removal And Installation................................................................................ 569 Lever And Wedge Disassembly And Assembly................................................................ 571 Pivot Pin Bushing And Seal Removal And Installation..................................................... 573 BOB-TACH (POWER)............................................................................................ 575 Description............................................................................................. 575 Removal And Installation................................................................................ 575 Lever And Wedge Disassembly And Assembly................................................................ 578 Pivot Pin Bushing And Seal Removal And Installation..................................................... 580 LIFT ARMS................................................................................................... 581 Stabilizer Bar Removal And Installation................................................................. 581 Link Removal And Installation........................................................................... 582 Removal And Installation................................................................................ 583 REAR GRILLE................................................................................................. 587 Removing................................................................................................ 587 Installing.............................................................................................. 587 REAR DOOR (TAILGATE)........................................................................................ 589 Removal And Installation................................................................................ 589 Striker Removal And Installation........................................................................ 590 Striker Disassembly And Assembly........................................................................ 590 Striker Adjusting....................................................................................... 591 Latch Removal And Installation.......................................................................... 591 FUEL TANK................................................................................................... 593 Removal And Installation................................................................................ 593 Fuel Level Sender Removal And Installation.............................................................. 596 Fuel Fill Screen Removal And Installation............................................................... 596 CONTROL PEDALS AND LINKAGES................................................................................. 597 Description............................................................................................. 597 Pedal Removal And Installation.......................................................................... 597 Linkage Removal And Installation........................................................................ 598 Pedal (Adjusting)....................................................................................... 599 Floor Pan Removal And Installation...................................................................... 600 CONTROL PEDALS AND LINKAGES (ACS)........................................................................... 601 Description............................................................................................. 601 Pedal Removal And Installation.......................................................................... 601 Linkage Removal And Installation........................................................................ 602 Pedal (Adjusting)....................................................................................... 602 Floor Pan Removal And Installation...................................................................... 603 CONTROL PANEL............................................................................................... 605 Description............................................................................................. 605 Removal And Installation................................................................................ 606 Disassembly And Assembly................................................................................ 607 Linkage Removal And Installation........................................................................ 611 Pintle Arm Disassembly And Assembly..................................................................... 615 Linkage Neutral (Adjusting)............................................................................. 616 Linkage Travel (Adjusting).............................................................................. 620 Shock Removal And Installation.......................................................................... 624 CONTROL PANEL (SJC)......................................................................................... 625 Description............................................................................................. 625 Removal And Installation................................................................................ 625 CONTROL HANDLE / LEVER...................................................................................... 627 Description............................................................................................. 627 Lever Removal And Installation.......................................................................... 627 Boot Removal And Installation........................................................................... 628 CONTROL HANDLE / LEVER (ACS)................................................................................ 629 Description............................................................................................. 629 Handle Sensor Removal And Installation.................................................................. 629 Handle Removal And Installation......................................................................... 632 Handle Disassembly And Assembly......................................................................... 633 Lever Removal And Installation.......................................................................... 633 Boot Removal And Installation........................................................................... 634 CONTROL HANDLE / LEVER (SJC)................................................................................ 635 Description............................................................................................. 635 Joystick Testing........................................................................................ 635 Joystick Removal And Installation....................................................................... 636 ACCESS PANEL (INSIDE)....................................................................................... 637 Removal And Installation (Left)......................................................................... 637 Removal And Installation (Right)........................................................................ 637 ACCESS PANEL (INSIDE) (SJC)................................................................................. 639 Removal And Installation (Left)......................................................................... 639 Removal And Installation (Right)........................................................................ 639 WINDOW (REAR)............................................................................................... 641 Removal And Installation................................................................................ 641 Removal And Installation (Latches)...................................................................... 641 Disassembly And Assembly (Latches)...................................................................... 642 Removal (Rubber Cord)................................................................................... 643 Installation (Rubber Cord).............................................................................. 644 WINDOW (TOP)................................................................................................ 647 Removal And Installation................................................................................ 647 WINDOW (SIDE)............................................................................................... 649 Removal And Installation................................................................................ 649 CAB DOOR.................................................................................................... 651 Description............................................................................................. 651 Removal And Installation................................................................................ 651 Disassembly And Assembly................................................................................ 652 Aligning................................................................................................ 653 Adjusting............................................................................................... 654 Checking Operation...................................................................................... 654 ARMREST..................................................................................................... 655 Description............................................................................................. 655 Removal And Installation................................................................................ 656 Disassembly And Assembly................................................................................ 657 LEFT SIDE LOWER PANEL....................................................................................... 659 Removal And Installation................................................................................ 659 Disassembly And Assembly................................................................................ 661 RIGHT SIDE LOWER PANEL...................................................................................... 663 Removal And Installation................................................................................ 663 Disassembly And Assembly................................................................................ 664 HEADLINER................................................................................................... 667 Removal And Installation................................................................................ 667 ELECTRICAL SYSTEM............................................................................................... 669 ELECTRICAL SCHEMATIC........................................................................................ 675 ELECTRICAL SYSTEM INFORMATION............................................................................... 885 Glossary Of Electrical Symbols.......................................................................... 885 Standard Cab Harness Connectors......................................................................... 888 Deluxe Cab Harness Connectors........................................................................... 889 Mainframe Harness Connectors - Manual Controls.......................................................... 890 Mainframe Harness Connectors - SJC...................................................................... 891 Description............................................................................................. 892 Troubleshooting......................................................................................... 893 Fuse And Relay Location / Identification................................................................ 894 Solenoid Testing........................................................................................ 898 BATTERY..................................................................................................... 899 Removal And Installation................................................................................ 899 Battery Maintenance..................................................................................... 900 Maintaining Battery Charge Level........................................................................ 900 Battery Service During Machine Storage.................................................................. 900 Battery Testing......................................................................................... 901 Battery Charging........................................................................................ 901 Using A Booster Battery (Jump Starting)................................................................. 902 ALTERNATOR.................................................................................................. 903 Belt Adjustment......................................................................................... 903 Belt Replacement........................................................................................ 903 Charging System Inspection.............................................................................. 904 Alternator Voltage Testing.............................................................................. 905 Low Voltage Testing..................................................................................... 905 High Voltage Testing.................................................................................... 906 Removal And Installation................................................................................ 907 Parts Identification.................................................................................... 909 STARTER..................................................................................................... 911 Testing................................................................................................. 911 Removal And Installation................................................................................ 911 Parts Identification.................................................................................... 912 INSTRUMENT PANELS........................................................................................... 913 Left Panel.............................................................................................. 913 Display Screen.......................................................................................... 915 Right Panel (Standard Key Panel)........................................................................ 916 Right Panel (Keyless Start Panel)....................................................................... 917 Right Panel (Deluxe Instrumentation Panel).............................................................. 918 Left Switch Panel....................................................................................... 920 Right Switch Panel...................................................................................... 920 Left Side Lower Panel................................................................................... 921 Right Side Lower Panel.................................................................................. 921 Left Panel Removal And Installation..................................................................... 922 Right Panel (Standard Key Panel) Removal And Installation............................................... 922 Right Panel (Keyless Start Panel) Removal And Installation.............................................. 923 Right Panel (Deluxe Instrumentation Panel) Removal And Installation..................................... 923 Key Switch Disassembly And Assembly..................................................................... 924 Alarm Disassembly And Assembly.......................................................................... 924 Left Switch Panel Removal And Installation.............................................................. 925 Right Switch Panel Removal And Installation............................................................. 925 LIGHTS...................................................................................................... 927 Front Removal And Installation.......................................................................... 927 Rear Removal And Installation........................................................................... 928 Cab Light Removal And Installation...................................................................... 928 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY).................................................................. 931 Description............................................................................................. 931 Connector Identification................................................................................ 932 Removal And Installation................................................................................ 938 BOBCAT CONTROLLER (ACS)..................................................................................... 939 Description............................................................................................. 939 Connector And Wire Identification....................................................................... 940 Removal And Installation................................................................................ 941 BOBCAT CONTROLLER (SJC) (DRIVE)............................................................................. 943 Description............................................................................................. 943 Connector Identification................................................................................ 944 Removal And Installation................................................................................ 946 DIAGNOSTIC SERVICE CODES.................................................................................... 947 Viewing Service Codes................................................................................... 947 Service Codes List...................................................................................... 948 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..................................................................... 955 Description............................................................................................. 955 Inspecting The BICS™ (Engine STOPPED - Key ON).......................................................... 956 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON).................... 956 Inspecting The Seat Bar Sensor (Engine RUNNING)......................................................... 956 Inspecting The Traction Lock And Parking Brake (Engine RUNNING)......................................... 956 Inspecting The Lift Arm Bypass Control.................................................................. 956 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)........................................ 956 Troubleshooting......................................................................................... 957 SEAT BAR SENSOR............................................................................................. 959 Description............................................................................................. 959 Troubleshooting......................................................................................... 959 Testing................................................................................................. 960 Removal................................................................................................. 961 Installation............................................................................................ 963 Bobcat Interlock Control System (BICS™) Circuit Test.................................................... 964 TRACTION LOCK............................................................................................... 967 Description............................................................................................. 967 Troubleshooting......................................................................................... 968 Inspecting.............................................................................................. 969 CONTROL SYSTEM (ACS)........................................................................................ 971 Description............................................................................................. 971 Troubleshooting......................................................................................... 972 Handle Sensor Connector Disassembly And Assembly........................................................ 973 Switch Handle Removal................................................................................... 974 Switch Handle Installation.............................................................................. 976 Actuator Connector Disassembly And Assembly............................................................. 979 Handle Lock Solenoid Removal And Installation........................................................... 980 Handle Lock Solenoid Disassembly And Assembly........................................................... 980 Foot Sensor Removal And Installation.................................................................... 981 Foot Sensor Disassembly And Assembly.................................................................... 982 Foot Sensor Lock Solenoid Removal And Installation...................................................... 982 ELECTRICAL / HYDRAULIC CONTROLS............................................................................. 983 Identification Chart.................................................................................... 983 Description............................................................................................. 984 Identification Chart ACD Group 0........................................................................ 985 Identification Chart ACD Group 1........................................................................ 986 Identification Chart ACD Group 2........................................................................ 987 Identification Chart ACD Group 3........................................................................ 988 ELECTRICAL / HYDRAULIC CONTROLS (ACS)....................................................................... 989 Identification Chart.................................................................................... 989 Description............................................................................................. 990 Identification Chart ACD Group 0........................................................................ 991 Identification Chart ACD Group 1........................................................................ 992 Identification Chart ACD Group 2........................................................................ 993 Identification Chart ACD Group 3........................................................................ 994 ELECTRICAL / HYDRAULIC CONTROLS (SJC)....................................................................... 995 Identification Chart.................................................................................... 995 Description............................................................................................. 996 Identification Chart ACD Group 0........................................................................ 997 Identification Chart ACD Group 1........................................................................ 998 Identification Chart ACD Group 2........................................................................ 999 Identification Chart ACD Group 3........................................................................1000 SERVICE PC (LAPTOP COMPUTER)................................................................................1001 Connecting Remote Start Tool............................................................................1001 Connecting Remote Start Tool (Service Tool).............................................................1001 CALIBRATION.................................................................................................1003 Description.............................................................................................1003 Actuator Testing........................................................................................1003 Lift And Tilt Calibration (SJC).........................................................................1006 Hydrostatic Pump Calibration (SJC)......................................................................1008 Lift And Tilt Calibration (ACS).........................................................................1013 STEERING DRIFT COMPENSATION (OPERATOR MODE).................................................................1015 Description.............................................................................................1015 Operation...............................................................................................1015 STEERING DRIFT COMPENSATION (SERVICE MODE)..................................................................1017 Description.............................................................................................1017 Operation...............................................................................................1017 FLYWHEEL RPM SENSOR.........................................................................................1019 Description.............................................................................................1019 Removal.................................................................................................1019 Installation............................................................................................1020 CONTROL PANEL SETUP.........................................................................................1021 Right Panel Setup (Deluxe Instrumentation Panel)........................................................1021 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...............................................................1025 Password Description....................................................................................1025 Changing The Owner Password.............................................................................1025 Changing The User Passwords.............................................................................1026 Password Lockout Feature................................................................................1026 PASSWORD SETUP (KEYLESS START PANEL)........................................................................1027 Password Description....................................................................................1027 Changing The Owner Password.............................................................................1027 Password Lockout Feature................................................................................1027 MAINTENANCE CLOCK...........................................................................................1029 Description.............................................................................................1029 Setup...................................................................................................1030 Reset...................................................................................................1033 BACK-UP ALARM SYSTEM........................................................................................1035 Description.............................................................................................1035 Inspecting..............................................................................................1035 Adjusting Switch Position...............................................................................1036 Troubleshooting (Standard And ACS)......................................................................1037 Troubleshooting (Joystick)..............................................................................1038 Alarm Removal And Installation..........................................................................1039 Switch Removal And Installation.........................................................................1039 FRONT HORN..................................................................................................1041 Removal And Installation................................................................................1041 Troubleshooting.........................................................................................1042 Troubleshooting (Joystick)..............................................................................1043 TELEMATICS..................................................................................................1045 Description.............................................................................................1045 Removal And Installation................................................................................1045 Procedure...............................................................................................1046 ENGINE SERVICE..................................................................................................1047 ENGINE INFORMATION..........................................................................................1051 Description.............................................................................................1051 Specifications..........................................................................................1052 Torque Values...........................................................................................1055 Troubleshooting.........................................................................................1055 Engine Removal And Installation.........................................................................1057 Engine Mount Replacement................................................................................1066 Compression - Testing...................................................................................1067 ENGINE SPEED CONTROL (HAND).................................................................................1069 Removal And Installation................................................................................1069 Disassembly And Assembly................................................................................1069 Cable Removal And Installation..........................................................................1070 ENGINE SPEED CONTROL (FOOT).................................................................................1071 Removal And Installation................................................................................1071 Disassembly And Assembly................................................................................1072 MUFFLER.....................................................................................................1075 Removal And Installation................................................................................1075 AIR CLEANER.................................................................................................1077 Housing Removal And Installation........................................................................1077 ENGINE COOLING SYSTEM (EARLIER MODELS)......................................................................1079 Radiator Removal And Installation.......................................................................1079 Hydraulic Fan Description...............................................................................1081 Fan Duct Removal And Installation.......................................................................1081 Hydraulic Fan Motor Assembly Removal And Installation...................................................1082 Hydraulic Fan Motor Removal And Installation............................................................1083 Hydraulic Fan Motor Disassembly And Assembly............................................................1085 Blower Housing Removal And Installation.................................................................1086 Water Pump Removal And Installation.....................................................................1087 Water Pump Disassembly And Assembly.....................................................................1087 Thermostat Housing Removal And Installation.............................................................1088 Thermostat - Testing....................................................................................1089 ENGINE COOLING SYSTEM (LATER MODELS)........................................................................1091 Radiator / Oil Cooler Removal And Installation..........................................................1091 Hydraulic Fan Description...............................................................................1094 Reversible Hydraulic Fan Description....................................................................1094 Fan Duct Removal And Installation.......................................................................1094 Hydraulic Fan Motor Assembly Removal And Installation...................................................1095 Hydraulic Fan Motor Removal And Installation............................................................1096 Hydraulic Fan Motor Disassembly And Assembly............................................................1098 Blower Housing Removal And Installation.................................................................1106 Water Pump Removal And Installation.....................................................................1107 Water Pump Disassembly And Assembly.....................................................................1107 Thermostat Housing Removal And Installation.............................................................1108 Thermostat - Testing....................................................................................1109 LUBRICATION SYSTEM..........................................................................................1111 Oil Pan Removal And Installation........................................................................1111 Oil Pump Removal And Installation.......................................................................1111 Relief Valve - Testing..................................................................................1112 Oil Pump Inspection.....................................................................................1112 Oil Filter Cooler Removal And Installation..............................................................1113 Engine Oil Pressure - Testing...........................................................................1114 FUEL SYSTEM.................................................................................................1115 Fuel Shutoff Solenoid - Testing.........................................................................1115 Fuel Shutoff Solenoid Removal And Installation..........................................................1115 Fuel Injection Pump - Testing...........................................................................1116 Fuel Injection Pump Assembly Removal And Installation...................................................1117 Governor Housing Disassembly And Assembly...............................................................1120 Governor Disassembly And Assembly.......................................................................1122 Fuel Camshaft Removal And Installation..................................................................1124 Fuel Injection Pump Removal And Installation............................................................1127 Fuel Injection Pump - Timing............................................................................1129 Fuel Injector Removal And Installation..................................................................1130 Fuel Injector Nozzle Pressure - Testing.................................................................1132 Nozzle Spray Condition..................................................................................1132 Valve Seat Tightness....................................................................................1133 CYLINDER HEAD...............................................................................................1135 Glow Plugs - Testing....................................................................................1135 Glow Plugs Removal And Installation.....................................................................1135 Valve Clearance Adjustment..............................................................................1136 Valve Timing - Inspecting...............................................................................1137 Cylinder Head Removal And Installation..................................................................1138 Cylinder Head Disassembly And Assembly..................................................................1141 Cylinder Head - Servicing...............................................................................1142 Cylinder Head Top Clearance.............................................................................1143 Valve Guide - Inspecting................................................................................1144 Valve Guide Removal And Installation....................................................................1144 Reconditioning The Valve And Valve Seat.................................................................1145 Valve Spring............................................................................................1147 Valve Tappets...........................................................................................1148 Rocker Arm And Shaft - Inspecting.......................................................................1149 Bridge Arm And Bridge Arm Shaft - Inspecting............................................................1149 Bridge Arm Shaft - Removal And Installation.............................................................1150 Push Rod Alignment - Inspecting.........................................................................1151 CRANKSHAFT AND PISTONS......................................................................................1153 Piston And Connecting Rod Removal And Installation......................................................1153 Piston And Connecting Rod - Servicing...................................................................1154 Cylinder Bore - Inspecting..............................................................................1158 Connecting Rod Alignment................................................................................1158 Crankshaft Gear Removal And Installation................................................................1159 Crankshaft And Bearings Removal And Installation........................................................1160 Crankshaft And Bearings - Servicing.....................................................................1163 CAMSHAFT AND TIMING GEARS...................................................................................1167 Timing Gearcase Cover Removal...........................................................................1167 Timing Gearcase Cover Installation......................................................................1168 Timing Gears Backlash - Inspection......................................................................1171 Idler Gear And Camshaft Removal And Installation........................................................1171 Camshaft - Servicing....................................................................................1172 Idler Gear And Shaft - Servicing........................................................................1173 TURBOCHARGER................................................................................................1175 Description.............................................................................................1175 Testing.................................................................................................1175 Removal And Installation................................................................................1176 FLYWHEEL AND HOUSING........................................................................................1177 Flywheel Removal And Installation.......................................................................1177 Ring Gear Removal And Installation......................................................................1178 Housing Removal And Installation........................................................................1179 EXHAUST GAS RECIRCULATION (EGR) SYSTEM......................................................................1181 Description.............................................................................................1181 Testing.................................................................................................1182 Removal And Installation................................................................................1185 Disassembly And Assembly................................................................................1186 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)................................................................1187 AIR CONDITIONING SYSTEM FLOW................................................................................1189 Description.............................................................................................1189 Chart...................................................................................................1190 Components..............................................................................................1191 Safety Equipment........................................................................................1194 REGULAR MAINTENANCE.........................................................................................1195 Filters.................................................................................................1195 Belt Adjustment.........................................................................................1196 Belt Replacement........................................................................................1196 Air Conditioning Condenser..............................................................................1196 Air Conditioning Lubrication............................................................................1196 Air Conditioning Service Chart..........................................................................1197 Evaporator / Heater Coil................................................................................1198 TROUBLESHOOTING.............................................................................................1201 Blower Motor Does Not Operate...........................................................................1201 Blower Motor Operates Normally, But Air Flow Is Insufficient............................................1201 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............................1201 The Compressor Does Not Operate At All, Or Operates Improperly..........................................1201 Gauge Pressure Related Troubleshooting..................................................................1202 Troubleshooting Tree....................................................................................1204 Temperature / Pressure Chart............................................................................1208 Poor A/C Performance....................................................................................1210 HVAC Repair And Leaks...................................................................................1211 Electrical System.......................................................................................1212 Engine Coolant Bypassing The Heater Valve...............................................................1218 Heater Valve Not Opening Or Closing.....................................................................1219 SYSTEM CHARGING AND RECLAMATION.............................................................................1221 Refrigerant Identification..............................................................................1221 Reclamation And Charging With Recovery / Charging Unit..................................................1222 COMPRESSOR..................................................................................................1225 Removal And Installation................................................................................1225 Oil.....................................................................................................1226 Oil Check...............................................................................................1227 CONDENSER (EARLIER MODELS)..................................................................................1229 Removal And Installation................................................................................1229 CONDENSER (LATER MODELS)....................................................................................1231 Removal And Installation................................................................................1231 RECEIVER / DRIER (EARLIER MODELS)...........................................................................1233 Receiver / Drier Removal And Installation...............................................................1233 Pressure Relief Valve Removal And Installation..........................................................1234 Pressure Switch Removal And Installation................................................................1235 Schrader® Valve Removal And Installation................................................................1236 RECEIVER / DRIER (LATER MODELS).............................................................................1237 Receiver / Drier Removal And Installation...............................................................1237 Pressure Switch Removal And Installation................................................................1239 Schrader® Valve Removal And Installation................................................................1240 EVAPORATOR / HEATER UNIT....................................................................................1241 Removal And Installation................................................................................1241 THERMOSTAT..................................................................................................1243 Description.............................................................................................1243 Removal And Installation................................................................................1244 EXPANSION VALVE.............................................................................................1245 Removal And Installation................................................................................1245 EVAPORATOR COIL.............................................................................................1247 Removal And Installation................................................................................1247 HEATER COIL.................................................................................................1249 Removal And Installation................................................................................1249 BLOWER FAN..................................................................................................1251 Removal And Installation................................................................................1251 Disassembly And Assembly................................................................................1251 HEATER VALVE................................................................................................1255 Removal And Installation................................................................................1255 EVAPORATOR / HEATER COVER...................................................................................1257 Removing................................................................................................1257 Installing..............................................................................................1257 SPECIFICATIONS..................................................................................................1259 (T590) LOADER SPECIFICATIONS................................................................................1261 Machine Dimensions......................................................................................1261 Performance.............................................................................................1262 Engine..................................................................................................1262 Drive System............................................................................................1263 Controls................................................................................................1263 Hydraulic System........................................................................................1264 Electrical System.......................................................................................1265 Capacities..............................................................................................1265 Tracks..................................................................................................1266 Ground Pressure.........................................................................................1266 TECHINCAL SERVICE GUIDE SPECIFICATIONS......................................................................1267 Engine..................................................................................................1267 Engine Torques..........................................................................................1267 Cooling System..........................................................................................1267 Loader Torques..........................................................................................1268 Hydraulic / Hydrostatic System..........................................................................1268 Fuel Consumption........................................................................................1268 TORQUE SPECIFICATIONS FOR BOLTS.............................................................................1269 Torque For General SAE Bolts............................................................................1269 Torque For General Metric Bolts.........................................................................1270 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................................1271 Straight Thread O-ring Fitting..........................................................................1271 Flare Fitting...........................................................................................1272 Tubelines And Hoses.....................................................................................1272 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................................1273 Specifications..........................................................................................1273 CONVERSIONS.................................................................................................1275 Decimal And Millimeter Equivalent Chart.................................................................1275 U.S. To Metric Conversion Chart.........................................................................1275 SERVICE TOOLS REQUIRED......................................................................................1277 Remote Start Tools......................................................................................1277 Hydraulic Tools.........................................................................................1278 Mainframe And Drive Tools...............................................................................1281 Electrical Tools........................................................................................1284 Engine Tools............................................................................................1285 HVAC Tools..............................................................................................1290 ALPHABETICAL INDEX..............................................................................................1291
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