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Bobcat T590 Compact Track Loader Service Manual 6990693 – PDF DOWNLOAD
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Bobcat T590 Compact Track Loader Service Manual 6990693 – PDF DOWNLOAD
S/N ALJU11001 & Above
S/N B37811001 & Above
S/N B3Z711001 & Above
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Description
Bobcat T590 Compact Track Loader Service Manual 6990693 – PDF DOWNLOAD
FILE DETAILS:
Bobcat T590 Compact Track Loader Service Manual 6990693 – PDF DOWNLOAD
Language : English
Pages : 1316
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T590 Compact Track Loader Service Manual 6990693 – PDF DOWNLOAD
S/N ALJU11001 & Above
S/N B37811001 & Above
S/N B3Z711001 & 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:
1. Check that the ROPS / FOPS (Including side screens) is in good condition and is not modified.
2. Check that ROPS mounting hardware is tightened and is Bobcat approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar must be correctly adjusted, clean and lubricated.
5. Check lift arm support device, replace if damaged.
6. Machine signs (decals) must be legible and in the correct location.
7. Steering levers, hand controls and foot pedals must return to neutral (as applicable).
8. Check for correct function of the work lights.
9. The parking brake must function correctly.
10. Enclosure door latches must open and close freely.
11. Bob-Tach® attachment mounting system wedges and linkages must function correctly and be in good condition.
12. Safety treads must be in good condition.
13. Check for correct function of indicator lamps.
14. Check all machine fluid levels.
15. Inspect for fuel, oil or hydraulic fluid leaks.
SAFETY INSTRUCTIONS:
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
TABLE OF CONTENTS:
Bobcat T590 Compact Track Loader Service Manual 6990693 – 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............................................................................. 21 Procedure............................................................................................... 21 LIFT ARM SUPPORT DEVICE..................................................................................... 23 Description............................................................................................. 23 Installing.............................................................................................. 24 Removing................................................................................................ 25 OPERATOR CAB................................................................................................ 27 Description............................................................................................. 27 Raising................................................................................................. 28 Lowering................................................................................................ 29 Cab Door Sensor......................................................................................... 30 Special Applications Kit................................................................................ 31 Special Applications Kit Inspection And Maintenance..................................................... 31 Forestry Door And Window Kit............................................................................ 32 Forestry Door And Window Kit Inspection And Maintenance................................................. 32 TRANSPORTING THE LOADER ON A TRAILER........................................................................ 33 Loading And Unloading................................................................................... 33 Fastening............................................................................................... 33 TOWING THE LOADER........................................................................................... 35 Procedure............................................................................................... 35 REMOTE START TOOL KIT - MEL1563............................................................................. 37 Remote Start Tool - MEL1563............................................................................. 37 Service Tool Harness Communicator - MEL1566............................................................. 39 Remote Start Procedure.................................................................................. 39 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666.............................................................. 43 Description............................................................................................. 43 Remote Start Tool (Service Tool) - 7022042.............................................................. 44 Loader Service Tool Harness - 6689747................................................................... 45 Computer Service Tool Harness - 6689746................................................................. 46 Remote Start Procedure.................................................................................. 47 SERVICE SCHEDULE............................................................................................ 51 Maintenance Intervals................................................................................... 51 ENGINE AIR CLEANER.......................................................................................... 53 Replacing Filter Elements............................................................................... 53 ENGINE COOLING SYSTEM....................................................................................... 55 Maintenance Platform.................................................................................... 55 Cleaning................................................................................................ 55 Checking And Adding Coolant............................................................................. 58 Removing And Replacing Coolant.......................................................................... 59 FUEL SYSTEM................................................................................................. 61 Fuel Specifications..................................................................................... 61 Biodiesel Blend Fuel.................................................................................... 61 Filling The Fuel Tank................................................................................... 62 Fuel Filter............................................................................................. 63 Removing Air From The Fuel System....................................................................... 64 ENGINE LUBRICATION SYSTEM................................................................................... 65 Checking And Adding Engine Oil.......................................................................... 65 Engine Oil Chart........................................................................................ 65 Removing And Replacing Oil And Filter................................................................... 66 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................................. 69 Checking And Adding Fluid............................................................................... 69 Hydraulic / Hydrostatic Fluid Chart..................................................................... 69 Removing And Replacing Hydraulic Fluid.................................................................. 70 Removing And Replacing Hydraulic / Hydrostatic Filter................................................... 72 Removing And Replacing Hydraulic Charge Filter.......................................................... 73 Replacing Reservoir Breather Cap........................................................................ 75 BOB-TACH (HAND LEVER)....................................................................................... 77 Inspection And Maintenance.............................................................................. 77 BOB-TACH (POWER)............................................................................................ 79 Inspection And Maintenance.............................................................................. 79 LUBRICATING THE LOADER...................................................................................... 81 Lubrication Locations................................................................................... 81 Track Roller And Idler Lubrication...................................................................... 84 PIVOT PINS.................................................................................................. 85 Inspection And Maintenance.............................................................................. 85 LOADER STORAGE AND RETURN TO SERVICE........................................................................ 87 Storage................................................................................................. 87 Return To Service....................................................................................... 87 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................................. 89 Procedure............................................................................................... 89 EMERGENCY EXIT.............................................................................................. 91 Rear Window Identification.............................................................................. 91 Rear Window Removal (Latches)........................................................................... 91 Rear Window Removal (Rubber Cord)....................................................................... 92 External Access (Rear Window With Latches).............................................................. 92 External Access (Rear Window With Rubber Cord).......................................................... 93 Front Door.............................................................................................. 94 SEAT BELT................................................................................................... 97 Inspection And Maintenance.............................................................................. 97 HYDRAULIC SYSTEM................................................................................................ 99 HYDRAULIC/HYDROSTATIC SCHEMATIC............................................................................. 103 HYDRAULIC SYSTEM INFORMATION................................................................................ 123 Glossary Of Hydraulic / Hydrostatic Symbols............................................................. 123 Troubleshooting......................................................................................... 127 CYLINDER (LIFT)............................................................................................. 129 Testing................................................................................................. 129 Removal And Installation................................................................................ 130 Parts Identification.................................................................................... 134 Disassembly............................................................................................. 135 Assembly................................................................................................ 137 CYLINDER (TILT)............................................................................................. 141 Testing................................................................................................. 141 Removal And Installation................................................................................ 142 Base End Pivot Pin Removal And Installation............................................................. 143 Parts Identification.................................................................................... 144 Disassembly............................................................................................. 145 Assembly................................................................................................ 147 CYLINDER (LIFT) (S/N B3Z711255 & ABOVE)..................................................................... 151 Testing................................................................................................. 151 Removal And Installation................................................................................ 152 Parts Identification.................................................................................... 156 Disassembly............................................................................................. 157 Assembly................................................................................................ 159 CYLINDER (TILT) (S/N B3Z711255 & ABOVE)..................................................................... 163 Testing................................................................................................. 163 Removal And Installation................................................................................ 164 Base End Pivot Pin Removal And Installation............................................................. 165 Parts Identification.................................................................................... 166 Disassembly............................................................................................. 167 Assembly................................................................................................ 169 CYLINDER (BOB-TACH)......................................................................................... 173 Testing................................................................................................. 173 Removal And Installation................................................................................ 174 Parts Identification.................................................................................... 175 Disassembly............................................................................................. 176 Assembly................................................................................................ 178 MAIN RELIEF VALVE........................................................................................... 181 Description............................................................................................. 181 Testing................................................................................................. 182 Adjusting............................................................................................... 184 Removal And Installation................................................................................ 185 HYDRAULIC CONTROL VALVE (STANDARD).......................................................................... 187 Description............................................................................................. 187 Removal And Installation................................................................................ 188 Mount Bracket Removal And Installation.................................................................. 191 Identification Chart.................................................................................... 192 Lift Load Check Valve Removal And Installation.......................................................... 193 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................................... 194 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................................... 195 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........................... 195 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........................... 196 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............................ 196 Port Relief Valve Removal And Installation.............................................................. 197 Plug Removal And Installation........................................................................... 199 Rubber Boot Removal And Installation.................................................................... 200 End Cap Block Removal And Installation.................................................................. 200 Lift Spool And Detent Removal And Installation.......................................................... 201 Tilt Spool Removal And Installation..................................................................... 209 Auxiliary Spool Removal And Installation................................................................ 211 Auxiliary Solenoid Removal And Installation............................................................. 212 Solenoid Removal And Installation....................................................................... 213 Lock Valve Removal And Installation..................................................................... 214 Lift Arm Bypass Orifice Removal And Installation........................................................ 216 Main Relief Valve Removal And Installation.............................................................. 216 Check Valve Removal And Installation.................................................................... 217 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)...................................................................... 219 Description............................................................................................. 219 Removal And Installation................................................................................ 219 Actuator Removal And Installation (In Loader)........................................................... 224 Actuator Removal And Installation (Out Of Loader)....................................................... 226 Identification Chart.................................................................................... 229 Mount Bracket Removal And Installation.................................................................. 230 Lift Load Check Valve Removal And Installation.......................................................... 230 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................................... 231 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................................... 232 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........................... 232 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........................... 233 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............................ 233 Port Relief Valve Removal And Installation.............................................................. 234 Plug Removal And Installation........................................................................... 236 End Cap Block Removal And Installation.................................................................. 237 Lift Spool Removal And Installation..................................................................... 237 Lift Spool Disassembly And Assembly..................................................................... 239 Tilt Spool Removal And Installation..................................................................... 240 Auxiliary Spool Removal And Installation................................................................ 242 Auxiliary Solenoid Removal And Installation............................................................. 243 Solenoid Removal And Installation....................................................................... 244 Lock Valve Removal And Installation..................................................................... 245 Lift Arm Bypass Orifice Removal And Installation........................................................ 247 Main Relief Valve Removal And Installation.............................................................. 247 Check Valve Removal And Installation.................................................................... 248 LIFT ARM BYPASS CONTROL VALVE............................................................................... 249 Description............................................................................................. 249 Testing................................................................................................. 249 Removal And Installation................................................................................ 250 Bracket Removal And Installation........................................................................ 251 Disassembly And Assembly................................................................................ 251 HYDRAULIC PUMP.............................................................................................. 253 Description............................................................................................. 253 Pump Test At Quick Couplers............................................................................. 254 Direct Pump Test (Standard Section)..................................................................... 256 Direct Pump Test (Charge Section)....................................................................... 258 Removal And Installation................................................................................ 260 Hydraulic Pump Startup.................................................................................. 262 Parts Identification.................................................................................... 263 Disassembly And Assembly................................................................................ 264 HYDRAULIC PUMP (HIGH FLOW).................................................................................. 265 Description............................................................................................. 265 Pump Test At Quick Couplers............................................................................. 266 Direct Pump Test (Standard Section)..................................................................... 268 Direct Pump Test (Charge Section)....................................................................... 269 Direct Pump Test (High Flow Section).................................................................... 271 High Flow Relief Valve Adjustment....................................................................... 273 High Flow Relief Valve Removal And Installation......................................................... 274 Solenoid Removal And Installation....................................................................... 275 Removal And Installation................................................................................ 276 Hydraulic Pump Startup.................................................................................. 278 Parts Identification.................................................................................... 279 Disassembly And Assembly................................................................................ 280 HYDRAULIC / HYDROSTATIC FILTERS............................................................................. 281 Description............................................................................................. 281 Housing Removal And Installation........................................................................ 281 HYDRAULIC FLUID RESERVOIR................................................................................... 283 Description............................................................................................. 283 Removal And Installation................................................................................ 283 Hydraulic Fluid Screen.................................................................................. 284 OIL COOLER.................................................................................................. 285 Description............................................................................................. 285 Removal And Installation................................................................................ 285 BUCKET POSITION VALVE....................................................................................... 287 Description............................................................................................. 287 Solenoid Removal And Installation....................................................................... 287 Solenoid Testing........................................................................................ 289 Removal And Installation................................................................................ 289 Disassembly And Assembly................................................................................ 291 REAR AUXILIARY DIVERTER VALVE............................................................................... 293 Description............................................................................................. 293 Solenoid Testing........................................................................................ 293 Removal And Installation................................................................................ 294 Disassembly And Assembly................................................................................ 295 BOB-TACH (POWER) BLOCK (S/N ALJU11001 - ALJU15134 AND B37811001 - B37811048)................................ 301 Description............................................................................................. 301 Removal And Installation................................................................................ 301 Disassembly And Assembly................................................................................ 303 BOB-TACH (POWER) BLOCK (S/N ALJU15135 AND B37811049 & ABOVE)................................................ 311 Description............................................................................................. 311 Testing Relief Valve.................................................................................... 312 Removal And Installation................................................................................ 314 Disassembly And Assembly................................................................................ 316 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK..................................................................... 321 Description............................................................................................. 321 Removal And Installation................................................................................ 322 Disassembly And Assembly (FFI/FI)....................................................................... 322 Disassembly And Assembly (FFH/FH)....................................................................... 324 AUTOMATIC RIDE CONTROL...................................................................................... 327 Description............................................................................................. 327 Removal And Installation................................................................................ 328 Checking The Pressure In The Accumulator................................................................ 331 Adding Nitrogen To The Accumulator...................................................................... 333 HYDROSTATIC SYSTEM.............................................................................................. 335 HYDROSTATIC SYSTEM INFORMATION.............................................................................. 337 Description............................................................................................. 337 Troubleshooting......................................................................................... 338 HYDROSTATIC DRIVE MOTOR (S/N ALJU11001 - ALJU19178 AND B37811001 - B37812060)............................... 339 Description............................................................................................. 339 Removing And Replacing Fluid............................................................................ 340 Removal And Installation................................................................................ 342 Parts Identification.................................................................................... 344 Disassembly............................................................................................. 346 Assembly................................................................................................ 354 HYDROSTATIC DRIVE MOTOR (S/N ALJU19179 AND B37812061 & ABOVE)............................................... 363 Description............................................................................................. 363 Removing And Replacing Fluid............................................................................ 364 Removal And Installation................................................................................ 365 Parts Identification (MCR5T)............................................................................ 367 Parts Identification (MCR6T) (Two-Speed)................................................................ 368 Disassembly And Assembly................................................................................ 369 CHARGE PRESSURE............................................................................................. 379 Description............................................................................................. 379 Testing................................................................................................. 380 Adjusting............................................................................................... 382 Sender Removal And Installation (Earlier Models)........................................................ 384 Sender Removal And Installation (Later Models).......................................................... 384 HYDROSTATIC PUMP............................................................................................ 385 Description............................................................................................. 385 Removal And Installation................................................................................ 386 Hydrostatic Pump Startup................................................................................ 387 Replenishing / High Pressure Relief Valve Removal And Installation...................................... 388 Parts Identification (Left Half)........................................................................ 389 Parts Identification (Right Half)....................................................................... 390 Disassembly............................................................................................. 391 Assembly................................................................................................ 398 HYDROSTATIC PUMP (SJC)...................................................................................... 405 Description............................................................................................. 405 Hydraulic Controller Removal And Installation........................................................... 406 Removal And Installation................................................................................ 408 Hydrostatic Pump Startup................................................................................ 410 Parts Identification.................................................................................... 411 High Pressure Relief And Bypass Valve................................................................... 412 Charge Relief Valve..................................................................................... 413 Disassembly And Assembly................................................................................ 414 Mechanical Neutral Adjustment........................................................................... 427 Hydraulic Controller Neutral Adjustment................................................................. 430 HYDROSTATIC PUMP (SJC) (S/N ALJU26335 & ABOVE).............................................................. 433 Description............................................................................................. 433 Port Locations And Gauge Installation................................................................... 434 Removal And Installation................................................................................ 435 Hydrostatic Pump Startup................................................................................ 437 Parts Identification.................................................................................... 438 High Pressure Relief And Bypass Valve................................................................... 441 Charge Pressure Relief Valve............................................................................ 442 Disassembly And Assembly................................................................................ 443 Mechanical Neutral Adjustment........................................................................... 455 Hydraulic Controller Neutral Adjustment................................................................. 457 DRIVE BELT.................................................................................................. 461 Belt Adjustment......................................................................................... 461 Stop Adjustment......................................................................................... 461 Belt Replacement........................................................................................ 462 Tensioner Pulley Removal And Installation (Earlier Models).............................................. 464 Tensioner Pulley Disassembly And Assembly............................................................... 464 Tensioner Pulley Removal And Installation (Later Models)................................................ 465 Tensioner Pulley Disassembly And Assembly............................................................... 465 TWO-SPEED / BRAKE VALVE..................................................................................... 467 Description............................................................................................. 467 Valve Block Removal And Installation.................................................................... 468 Valve Block Disassembly And Assembly.................................................................... 470 DRAIN MANIFOLD.............................................................................................. 473 Description............................................................................................. 473 Drain Manifold Removal And Installation................................................................. 473 DRIVE SYSTEM.................................................................................................... 475 BRAKE....................................................................................................... 477 Description............................................................................................. 477 Block Removal And Installation.......................................................................... 477 Block Disassembly And Assembly.......................................................................... 479 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N ALJU11001 - ALJU18000 AND B37811001 - B37812000)........ 481 Description............................................................................................. 481 Checking Tension........................................................................................ 482 Adjusting Tension....................................................................................... 483 Track Removal And Installation.......................................................................... 485 Idler (Front) Removal And Installation.................................................................. 487 Track Tensioner Disassembly And Assembly................................................................ 490 Idler (Rear) Removal And Installation................................................................... 492 Roller Removal And Installation......................................................................... 492 Sprocket Removal And Installation....................................................................... 493 Track Housing Removal And Installation.................................................................. 494 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N ALJU11001 - ALJU18000 AND B37811001 - B37812000).... 497 Description............................................................................................. 497 Checking Tension........................................................................................ 498 Adjusting Tension....................................................................................... 499 Track Removal And Installation.......................................................................... 501 Idler (Front) Removal And Installation.................................................................. 503 Track Tensioner Disassembly And Assembly................................................................ 506 Idler (Rear) Removal And Installation................................................................... 508 Roller Removal And Installation......................................................................... 508 Leaf Spring Removal And Installation.................................................................... 509 Sprocket Removal And Installation....................................................................... 510 Track Housing Removal And Installation.................................................................. 511 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N ALJU18001 AND B37812001 & ABOVE)........................ 513 Description............................................................................................. 513 Checking (Solid-Mounted Undercarriage).................................................................. 515 Adjusting (Solid-Mounted Undercarriage) (Earlier Models With Two Track Tension Fittings)................ 516 Adjusting (Solid-Mounted Undercarriage) (Later Models With One Track Tension Fitting)................... 517 Track Removal And Installation.......................................................................... 518 Idler (Front) Removal And Installation.................................................................. 521 Track Tensioner Removal And Installation................................................................ 522 Track Tensioner Disassembly And Assembly................................................................ 523 Idler (Rear) Removal And Installation................................................................... 525 Roller Removal And Installation......................................................................... 525 Sprocket Removal And Installation (Twelve Bolt Sprocket)................................................ 526 Sprocket Removal And Installation (Sixteen Bolt Sprocket)............................................... 526 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N ALJU18001 AND B37812001 & ABOVE).................... 527 Description............................................................................................. 527 Checking (Roller Suspension Undercarriage).............................................................. 529 Adjusting (Roller Suspension Undercarriage) (Earlier Models With Two Track Tension Fittings)............ 530 Adjusting (Roller Suspension Undercarriage) (Later Models With One Track Tension Fitting)............... 531 Track Removal And Installation.......................................................................... 532 Idler (Front) Removal And Installation.................................................................. 535 Track Tensioner Removal And Installation................................................................ 536 Track Tensioner Disassembly And Assembly................................................................ 537 Idler (Rear) Removal And Installation................................................................... 539 Roller Removal And Installation......................................................................... 539 Leaf Spring Removal And Installation.................................................................... 540 Sprocket Removal And Installation (Twelve Bolt Sprocket)................................................ 541 Sprocket Removal And Installation (Sixteen Bolt Sprocket)............................................... 541 TRACK MAINTENANCE........................................................................................... 543 Track Damage Identification............................................................................. 543 MAINFRAME....................................................................................................... 555 SEAT BAR.................................................................................................... 559 Description............................................................................................. 559 Removal And Installation................................................................................ 559 Disassembly And Assembly................................................................................ 560 Compression Spring Disassembly And Assembly............................................................. 561 OPERATOR CAB................................................................................................ 563 Gas Spring Removal And Installation..................................................................... 563 Gas Spring Bracket Disassembly And Assembly............................................................. 564 Removal And Installation................................................................................ 564 OPERATOR SEAT (SUSPENSION).................................................................................. 567 Removal And Installation................................................................................ 567 Slide Rail Removal And Installation..................................................................... 567 Seat Belt Removal And Installation...................................................................... 568 Lower Cushion Removal................................................................................... 568 Lower Cushion Installation.............................................................................. 569 Back Cushion Removal And Installation................................................................... 569 Shock Removal And Installation.......................................................................... 570 3-Point Seat Belt Removal And Installation.............................................................. 570 BOB-TACH (HAND LEVER)....................................................................................... 573 Description............................................................................................. 573 Removal And Installation................................................................................ 573 Lever And Wedge Disassembly And Assembly................................................................ 576 Pivot Pin Bushing And Seal Removal And Installation..................................................... 578 BOB-TACH (POWER)............................................................................................ 579 Description............................................................................................. 579 Removal And Installation................................................................................ 579 Lever And Wedge Disassembly And Assembly................................................................ 582 Pivot Pin Bushing And Seal Removal And Installation..................................................... 584 LIFT ARMS................................................................................................... 585 Stabilizer Bar Removal And Installation................................................................. 585 Link Removal And Installation........................................................................... 586 Removal And Installation................................................................................ 587 REAR GRILLE................................................................................................. 591 Removing................................................................................................ 591 Installing.............................................................................................. 591 Shield Removal And Installation......................................................................... 592 REAR DOOR (TAILGATE)........................................................................................ 593 Removal And Installation................................................................................ 593 Striker Removal And Installation........................................................................ 594 Striker Disassembly And Assembly........................................................................ 594 Striker (Adjusting)..................................................................................... 595 Latch Removal And Installation.......................................................................... 596 FUEL TANK................................................................................................... 597 Removal And Installation................................................................................ 597 Fuel Level Sender Removal And Installation.............................................................. 599 Fuel Fill Screen Removal And Installation............................................................... 599 CONTROL PEDALS AND LINKAGES................................................................................. 601 Description............................................................................................. 601 Pedal Removal And Installation.......................................................................... 601 Linkage Removal And Installation........................................................................ 602 Pedal (Adjusting)....................................................................................... 603 Floor Pan Removal And Installation...................................................................... 604 CONTROL PEDALS AND LINKAGES (ACS)........................................................................... 605 Description............................................................................................. 605 Pedal Removal And Installation.......................................................................... 605 Linkage Removal And Installation........................................................................ 606 Pedal (Adjusting)....................................................................................... 606 Floor Pan Removal And Installation...................................................................... 607 CONTROL PANEL............................................................................................... 609 Description............................................................................................. 609 Removal And Installation................................................................................ 610 Disassembly And Assembly................................................................................ 611 Linkage Removal And Installation........................................................................ 616 Pintle Arm Disassembly And Assembly..................................................................... 619 Linkage Neutral (Adjusting)............................................................................. 620 Linkage Travel (Adjusting).............................................................................. 624 Shock Removal And Installation.......................................................................... 628 CONTROL PANEL (SJC)......................................................................................... 629 Description............................................................................................. 629 Removal And Installation................................................................................ 629 CONTROL HANDLE / LEVER...................................................................................... 631 Description............................................................................................. 631 Lever Removal And Installation.......................................................................... 631 Boot Removal And Installation........................................................................... 632 CONTROL HANDLE / LEVER (ACS)................................................................................ 633 Description............................................................................................. 633 Handle Sensor Removal And Installation.................................................................. 633 Handle Removal And Installation......................................................................... 636 Handle Disassembly And Assembly......................................................................... 637 Lever Removal And Installation.......................................................................... 637 Boot Removal And Installation........................................................................... 638 CONTROL HANDLE / LEVER (SJC)................................................................................ 639 Description............................................................................................. 639 Joystick Testing........................................................................................ 639 Joystick Removal And Installation....................................................................... 640 ACCESS PANEL (INSIDE)....................................................................................... 641 Removal And Installation (Left)......................................................................... 641 Removal And Installation (Right)........................................................................ 641 ACCESS PANEL (INSIDE) (SJC)................................................................................. 643 Removal And Installation (Left)......................................................................... 643 Removal And Installation (Right)........................................................................ 643 WINDOW (REAR)............................................................................................... 645 Rear Window Identification.............................................................................. 645 Removal And Installation (Latches)...................................................................... 645 Disassembly And Assembly (Latches)...................................................................... 646 Removal (Rubber Cord)................................................................................... 647 Installation (Rubber Cord).............................................................................. 648 WINDOW (TOP)................................................................................................ 651 Removal And Installation................................................................................ 651 WINDOW (SIDE)............................................................................................... 653 Removal And Installation................................................................................ 653 CAB DOOR.................................................................................................... 655 Description............................................................................................. 655 Removal And Installation................................................................................ 655 Disassembly And Assembly................................................................................ 656 Aligning................................................................................................ 657 Adjusting............................................................................................... 658 Checking Operation...................................................................................... 658 ARMREST..................................................................................................... 659 Description............................................................................................. 659 Removal And Installation................................................................................ 660 Disassembly And Assembly................................................................................ 661 LEFT SIDE LOWER PANEL....................................................................................... 663 Removal And Installation................................................................................ 663 Disassembly And Assembly................................................................................ 665 RIGHT SIDE LOWER PANEL...................................................................................... 667 Removal And Installation................................................................................ 667 Disassembly And Assembly................................................................................ 668 HEADLINER................................................................................................... 671 Removal And Installation................................................................................ 671 FAN DUCT PANELS............................................................................................. 673 Removal And Installation................................................................................ 673 ELECTRICAL SYSTEM............................................................................................... 675 ELECTRICAL SCHEMATIC........................................................................................ 681 ELECTRICAL SYSTEM INFORMATION............................................................................... 887 Glossary Of Electrical Symbols.......................................................................... 887 Standard Cab Harness Connectors......................................................................... 890 Deluxe Cab Harness Connectors........................................................................... 891 Mainframe Harness Connectors - Manual Controls.......................................................... 892 Mainframe Harness Connectors - SJC...................................................................... 893 Description............................................................................................. 894 Troubleshooting......................................................................................... 895 Fuse And Relay Location / Identification................................................................ 896 Solenoid Testing........................................................................................ 899 BATTERY..................................................................................................... 901 Removal And Installation................................................................................ 901 Battery Maintenance..................................................................................... 902 Maintaining Battery Charge Level........................................................................ 902 Battery Service During Machine Storage.................................................................. 902 Battery Testing......................................................................................... 903 Battery Charging........................................................................................ 903 Using A Booster Battery (Jump Starting)................................................................. 904 ALTERNATOR.................................................................................................. 905 Belt Adjustment......................................................................................... 905 Belt Replacement........................................................................................ 905 Charging System Inspection.............................................................................. 906 Alternator Voltage Testing.............................................................................. 907 Low Voltage Testing..................................................................................... 907 High Voltage Testing.................................................................................... 908 Removal And Installation................................................................................ 909 Parts Identification.................................................................................... 911 STARTER..................................................................................................... 913 Testing................................................................................................. 913 Removal And Installation................................................................................ 913 Parts Identification.................................................................................... 914 INSTRUMENT PANELS........................................................................................... 915 Left Panel.............................................................................................. 915 Display Screen.......................................................................................... 917 Right Panel (Standard Key Panel)........................................................................ 918 Right Panel (Keyless Start Panel)....................................................................... 919 Right Panel (Deluxe Instrumentation Panel).............................................................. 920 Left Switch Panel....................................................................................... 922 Right Switch Panel...................................................................................... 922 Left Side Lower Panel................................................................................... 923 Right Side Lower Panel.................................................................................. 923 Left Panel Removal And Installation..................................................................... 924 Right Panel (Standard Key Panel) Removal And Installation............................................... 924 Right Panel (Keyless Start Panel) Removal And Installation.............................................. 925 Right Panel (Deluxe Instrumentation Panel) Removal And Installation..................................... 925 Key Switch Disassembly And Assembly..................................................................... 926 Alarm Disassembly And Assembly.......................................................................... 926 Left Switch Panel Removal And Installation.............................................................. 927 Right Switch Panel Removal And Installation............................................................. 927 LIGHTS...................................................................................................... 929 Front Removal And Installation.......................................................................... 929 Rear Removal And Installation........................................................................... 930 Cab Light Removal And Installation...................................................................... 930 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 ENGINE CONTROL UNIT (ECU)................................................................................... 947 Description............................................................................................. 947 Cleaning................................................................................................ 948 Removal And Installation................................................................................ 949 DIAGNOSTIC SERVICE CODES.................................................................................... 951 Viewing Service Codes................................................................................... 951 Service Codes List...................................................................................... 952 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..................................................................... 961 Description............................................................................................. 961 Inspecting The BICS™ (Engine STOPPED - Key ON).......................................................... 962 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON).................... 962 Inspecting The Seat Bar Sensor (Engine RUNNING)......................................................... 962 Inspecting The Traction Lock And Parking Brake (Engine RUNNING)......................................... 962 Inspecting The Lift Arm Bypass Control.................................................................. 962 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)........................................ 962 Troubleshooting......................................................................................... 963 SEAT BAR SENSOR............................................................................................. 965 Description............................................................................................. 965 Troubleshooting......................................................................................... 965 Testing................................................................................................. 966 Removal................................................................................................. 967 Installation............................................................................................ 969 Bobcat Interlock Control System (BICS™) Circuit Test.................................................... 970 TRACTION LOCK............................................................................................... 973 Description............................................................................................. 973 Troubleshooting......................................................................................... 974 Inspecting.............................................................................................. 975 CONTROL SYSTEM (ACS)........................................................................................ 977 Description............................................................................................. 977 Troubleshooting......................................................................................... 978 Handle Sensor Connector Disassembly And Assembly........................................................ 979 Switch Handle Removal................................................................................... 980 Switch Handle Installation.............................................................................. 982 Actuator Connector Disassembly And Assembly............................................................. 985 Handle Lock Solenoid Removal And Installation........................................................... 986 Handle Lock Solenoid Disassembly And Assembly........................................................... 986 Foot Sensor Removal And Installation.................................................................... 987 Foot Sensor Disassembly And Assembly.................................................................... 988 Foot Sensor Lock Solenoid Removal And Installation...................................................... 988 ELECTRICAL / HYDRAULIC CONTROLS............................................................................. 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 (ACS)....................................................................... 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 ELECTRICAL / HYDRAULIC CONTROLS (SJC).......................................................................1001 Identification Chart....................................................................................1001 Description.............................................................................................1002 Identification Chart ACD Group 0........................................................................1003 Identification Chart ACD Group 1........................................................................1004 Identification Chart ACD Group 2........................................................................1005 Identification Chart ACD Group 3........................................................................1006 SERVICE PC (LAPTOP COMPUTER)................................................................................1007 Connecting Remote Start Tool............................................................................1007 Connecting Remote Start Tool (Service Tool).............................................................1007 CALIBRATION.................................................................................................1009 Description.............................................................................................1009 Actuator Testing........................................................................................1009 Lift And Tilt Calibration (SJC).........................................................................1012 Hydrostatic Pump Calibration (SJC)......................................................................1014 Lift And Tilt Calibration (ACS).........................................................................1019 STEERING DRIFT COMPENSATION (OPERATOR MODE).................................................................1021 Description.............................................................................................1021 Operation...............................................................................................1021 STEERING DRIFT COMPENSATION (SERVICE MODE)..................................................................1023 Description.............................................................................................1023 Operation...............................................................................................1023 CONTROL PANEL SETUP.........................................................................................1025 Right Panel Setup (Deluxe Instrumentation Panel)........................................................1025 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...............................................................1029 Password Description....................................................................................1029 Changing The Owner Password.............................................................................1029 Changing The User Passwords.............................................................................1030 Password Lockout Feature................................................................................1030 PASSWORD SETUP (KEYLESS START PANEL)........................................................................1031 Password Description....................................................................................1031 Changing The Owner Password.............................................................................1031 Password Lockout Feature................................................................................1031 MAINTENANCE CLOCK...........................................................................................1033 Description.............................................................................................1033 Setup...................................................................................................1034 Reset...................................................................................................1037 BACK-UP ALARM SYSTEM........................................................................................1039 Description.............................................................................................1039 Inspecting..............................................................................................1039 Adjusting Switch Position...............................................................................1040 Troubleshooting (Standard And ACS)......................................................................1041 Troubleshooting (Joystick)..............................................................................1042 Alarm Removal And Installation..........................................................................1043 Switch Removal And Installation.........................................................................1043 FRONT HORN..................................................................................................1045 Removal And Installation................................................................................1045 Troubleshooting.........................................................................................1046 Troubleshooting (Joystick)..............................................................................1047 ENGINE SPEED CONTROL (HAND).................................................................................1049 Removal And Installation................................................................................1049 ENGINE SPEED CONTROL (FOOT).................................................................................1051 Removal And Installation................................................................................1051 Disassembly And Assembly................................................................................1052 Foot Throttle Calibration...............................................................................1054 CAMSHAFT AND CRANKSHAFT POSITION SENSOR.....................................................................1057 Removal And Installation................................................................................1057 TELEMATICS..................................................................................................1059 Description.............................................................................................1059 Removal And Installation................................................................................1059 Procedure...............................................................................................1060 ENGINE SERVICE..................................................................................................1061 ENGINE INFORMATION..........................................................................................1065 Description.............................................................................................1065 Specifications..........................................................................................1066 Sensor Location.........................................................................................1068 Torque Values...........................................................................................1074 Troubleshooting.........................................................................................1076 Engine Removal And Installation.........................................................................1078 Engine Mount Replacement................................................................................1088 Compression - Testing...................................................................................1090 Injector Signal - Testing...............................................................................1092 Injector Signal - Testing (In-Line).....................................................................1094 Oil Pressure Testing (At Oil Sensor On Block)...........................................................1096 Oil Pressure Testing (At Turbocharger Oil Inlet)........................................................1098 DIESEL OXIDATION CATALYST (DOC).............................................................................1101 Removal And Installation................................................................................1101 AIR CLEANER.................................................................................................1103 Housing Removal And Installation........................................................................1103 ENGINE COOLING SYSTEM (EARLIER MODELS)......................................................................1105 Radiator / Oil Cooler Removal And Installation..........................................................1105 Hydraulic Fan Description...............................................................................1108 Fan Duct Removal And Installation.......................................................................1108 Hydraulic Fan Motor Assembly Removal And Installation...................................................1109 Hydraulic Fan Motor Removal And Installation............................................................1110 Hydraulic Fan Motor Disassembly And Assembly............................................................1112 Blower Housing Removal And Installation.................................................................1113 Water Pump Removal And Installation.....................................................................1114 Thermostat Housing Removal And Installation.............................................................1115 Testing The Thermostat..................................................................................1116 ENGINE COOLING SYSTEM (LATER MODELS)........................................................................1117 Radiator / Oil Cooler Removal And Installation..........................................................1117 Hydraulic Fan Description...............................................................................1119 Reversible Hydraulic Fan Description....................................................................1120 Fan Duct Removal And Installation.......................................................................1120 Hydraulic Fan Motor Assembly Removal And Installation...................................................1121 Hydraulic Fan Motor Removal And Installation............................................................1122 Hydraulic Fan Motor Disassembly And Assembly............................................................1124 Blower Housing Removal And Installation.................................................................1132 Water Pump Removal And Installation.....................................................................1133 Thermostat Housing Removal And Installation.............................................................1134 Testing The Thermostat..................................................................................1135 LUBRICATION SYSTEM..........................................................................................1137 Description.............................................................................................1137 Oil Pan Removal And Installation........................................................................1138 Oil Pump Removal And Installation.......................................................................1139 Oil Pump Relief Valve Description.......................................................................1140 Oil Pump Relief Valve Removal And Installation..........................................................1140 Oil Cooler Removal And Installation.....................................................................1141 Oil Filter Head Removal And Installation................................................................1142 Oil Cooler Bypass Description...........................................................................1143 Oil Cooler Bypass Removal And Installation..............................................................1143 FUEL SYSTEM.................................................................................................1145 Description.............................................................................................1145 Transfer Pump / High Pressure Pump Removal And Installation.............................................1146 Fuel Temperature Sensor Removal And Installation........................................................1148 Fuel Cooler Removal And Installation....................................................................1149 Fuel Bypass Valve Removal And Installation..............................................................1149 Fuel Recirculation Valve Removal And Installation.......................................................1150 Fuel Rail Assembly Removal And Installation.............................................................1151 Fuel Injector Removal And Installation..................................................................1152 Injector Coding.........................................................................................1154 Removing Air From The Fuel System.......................................................................1156 CYLINDER HEAD...............................................................................................1159 Glow Plugs Testing......................................................................................1159 Glow Plug Removal And Installation......................................................................1160 Valve Clearance Adjustment..............................................................................1161 Cylinder Head Removal And Installation..................................................................1163 Cylinder Head Disassembly And Assembly..................................................................1168 Cylinder Head Inspection................................................................................1169 Cylinder Head Top Clearance.............................................................................1170 Valve Step Height.......................................................................................1171 Valve Stem Height.......................................................................................1171 Valve Guide.............................................................................................1172 Valve...................................................................................................1172 Valve Spring............................................................................................1173 Rocker Arm Shaft Disassembly And Assembly...............................................................1174 Rocker Arm Shaft Inspection.............................................................................1175 Push Rod Inspection.....................................................................................1175 CRANKSHAFT AND PISTONS......................................................................................1177 Piston And Connecting Rod Removal And Installation......................................................1177 Piston And Connecting Rod Inspection....................................................................1178 Crankshaft Removal And Installation.....................................................................1180 Cylinder Block Inspection...............................................................................1183 Crankshaft Inspection...................................................................................1185 Connecting Rod Inspection...............................................................................1185 Engine Component Class..................................................................................1186 CAMSHAFT....................................................................................................1189 Removal And Installation................................................................................1189 Inspecting..............................................................................................1190 GEARCASE....................................................................................................1193 Gearcase Cover Removal And Installation.................................................................1193 Gear Backlash...........................................................................................1194 Gear Timing.............................................................................................1195 Idle Gear Removal And Installation......................................................................1196 Idle Gear Inspection....................................................................................1196 TURBOCHARGER................................................................................................1197 Description.............................................................................................1197 Removal And Installation................................................................................1197 Inspection..............................................................................................1200 FLYWHEEL AND HOUSING........................................................................................1201 Flywheel Removal And Installation.......................................................................1201 Ring Gear Removal And Installation......................................................................1202 Housing Removal And Installation........................................................................1202 EXHAUST GAS RECIRCULATION (EGR) SYSTEM......................................................................1203 Description.............................................................................................1203 Removal And Installation................................................................................1204 Disassembly And Assembly................................................................................1208 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)................................................................1211 AIR CONDITIONING SYSTEM FLOW................................................................................1213 Description.............................................................................................1213 Chart...................................................................................................1214 Components..............................................................................................1215 Safety Equipment........................................................................................1218 REGULAR MAINTENANCE.........................................................................................1219 Filters.................................................................................................1219 Belt Adjustment.........................................................................................1220 Belt Replacement........................................................................................1220 Air Conditioning Condenser..............................................................................1220 Air Conditioning Lubrication............................................................................1220 Air Conditioning Service Chart..........................................................................1221 Evaporator / Heater Coil................................................................................1222 TROUBLESHOOTING.............................................................................................1225 Blower Motor Does Not Operate...........................................................................1225 Blower Motor Operates Normally, But Air Flow Is Insufficient............................................1225 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............................1225 The Compressor Does Not Operate At All, Or Operates Improperly..........................................1225 Gauge Pressure Related Troubleshooting..................................................................1226 Troubleshooting Tree....................................................................................1228 Temperature / Pressure Chart............................................................................1232 Poor A/C Performance....................................................................................1234 HVAC Repair And Leaks...................................................................................1235 Electrical System.......................................................................................1236 Engine Coolant Bypassing The Heater Valve...............................................................1242 Heater Valve Not Opening Or Closing.....................................................................1243 SYSTEM CHARGING AND RECLAMATION.............................................................................1245 Refrigerant Identification..............................................................................1245 Reclamation And Charging With Recovery / Charging Unit..................................................1246 COMPRESSOR..................................................................................................1249 Removal And Installation................................................................................1249 Oil.....................................................................................................1251 Oil Check...............................................................................................1252 CONDENSER...................................................................................................1255 Removal And Installation................................................................................1255 RECEIVER / DRIER............................................................................................1257 Receiver / Drier Removal And Installation...............................................................1257 Pressure Switch Removal And Installation................................................................1259 Schrader® Valve Removal And Installation................................................................1260 EVAPORATOR / HEATER UNIT....................................................................................1261 Removal And Installation................................................................................1261 THERMOSTAT..................................................................................................1263 Description.............................................................................................1263 Removal And Installation................................................................................1264 EXPANSION VALVE.............................................................................................1265 Removal And Installation................................................................................1265 EVAPORATOR COIL.............................................................................................1267 Removal And Installation................................................................................1267 HEATER COIL.................................................................................................1269 Removal And Installation................................................................................1269 BLOWER FAN..................................................................................................1271 Removal And Installation................................................................................1271 Disassembly And Assembly................................................................................1271 HEATER VALVE................................................................................................1275 Removal And Installation................................................................................1275 EVAPORATOR / HEATER COVER...................................................................................1277 Removing................................................................................................1277 Installing..............................................................................................1277 SPECIFICATIONS..................................................................................................1279 (T590) LOADER SPECIFICATIONS................................................................................1281 Machine Dimensions......................................................................................1281 Performance.............................................................................................1282 Engine..................................................................................................1282 Drive System............................................................................................1283 Controls................................................................................................1283 Hydraulic System........................................................................................1284 Electrical System.......................................................................................1285 Capacities..............................................................................................1285 Tracks..................................................................................................1286 Ground Pressure.........................................................................................1286 TECHINCAL SERVICE GUIDE SPECIFICATIONS......................................................................1287 Engine..................................................................................................1287 Engine Torques..........................................................................................1287 Cooling System..........................................................................................1287 Loader Torques..........................................................................................1288 Hydraulic / Hydrostatic System..........................................................................1288 Fuel Consumption........................................................................................1288 TORQUE SPECIFICATIONS FOR BOLTS.............................................................................1289 Torque For General SAE Bolts............................................................................1289 Torque For General Metric Bolts.........................................................................1290 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................................1291 Straight Thread O-ring Fitting..........................................................................1291 Flare Fitting...........................................................................................1292 Tubelines And Hoses.....................................................................................1292 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................................1293 Specifications..........................................................................................1293 CONVERSIONS.................................................................................................1295 Decimal And Millimeter Equivalent Chart.................................................................1295 U.S. To Metric Conversion Chart.........................................................................1295 SERVICE TOOLS REQUIRED......................................................................................1297 Remote Start Tools......................................................................................1297 Hydraulic Tools.........................................................................................1298 Mainframe And Drive Tools...............................................................................1301 Electrical Tools........................................................................................1304 Engine Tools............................................................................................1305 HVAC Tools..............................................................................................1310 ALPHABETICAL INDEX..............................................................................................1311
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