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Bobcat T590 Compact Track Loader Service Manual SN B4KV11001 & Above – PDF DOWNLOAD
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Bobcat T590 Compact Track Loader Service Manual SN B4KV11001 & Above – PDF DOWNLOAD
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Description
Bobcat T590 Compact Track Loader Service Manual SN B4KV11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T590 Compact Track Loader Service Manual SN B4KV11001 & Above – PDF DOWNLOAD
Language : English
Pages : 926
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T590 Compact Track Loader Service Manual SN B4KV11001 & Above – PDF DOWNLOAD
FOREWORD:
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
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 SN B4KV11001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY.............................................................................. 3 CONTENTS........................................................................................ 5 FOREWORD........................................................................................ 7 FOREWORD.................................................................................... 9 SAFETY INSTRUCTIONS......................................................................... 11 FIRE PREVENTION............................................................................. 13 Maintenance............................................................................. 13 Operation............................................................................... 13 Electrical.............................................................................. 13 Hydraulic System........................................................................ 13 Fueling................................................................................. 13 Starting................................................................................ 13 Spark Arrester Exhaust System........................................................... 13 Welding And Grinding.................................................................... 14 Fire Extinguishers...................................................................... 14 SERIAL NUMBER LOCATIONS..................................................................... 15 Loader Serial Number.................................................................... 15 Engine Serial Number.................................................................... 15 DELIVERY REPORT............................................................................. 16 LOADER IDENTIFICATION....................................................................... 17 SAFETY AND MAINTENANCE.......................................................................... 19 LIFTING AND BLOCKING THE LOADER............................................................. 23 Procedure............................................................................... 23 LIFT ARM SUPPORT DEVICE..................................................................... 25 Description............................................................................. 25 Installing.............................................................................. 26 Removing................................................................................ 27 OPERATOR CAB................................................................................ 29 Description............................................................................. 29 Raising................................................................................. 30 Lowering................................................................................ 31 Cab Door Sensor......................................................................... 32 Special Applications Kit................................................................ 33 Special Applications Kit Inspection And Maintenance..................................... 33 Forestry Door And Window Kit............................................................ 34 Forestry Door And Window Kit Inspection And Maintenance................................. 34 TRANSPORTING THE LOADER ON A TRAILER........................................................ 35 Loading And Unloading................................................................... 35 Fastening............................................................................... 35 TOWING THE LOADER........................................................................... 37 Procedure............................................................................... 37 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666.............................................. 39 Description............................................................................. 39 Remote Start Tool (Service Tool) - 7022042.............................................. 40 Loader Service Tool Harness - 6689747................................................... 41 Computer Service Tool Harness - 6689746................................................. 42 Remote Start Procedure.................................................................. 43 SERVICE SCHEDULE............................................................................ 47 Maintenance Intervals................................................................... 47 ENGINE AIR CLEANER.......................................................................... 49 Replacing Filter Elements............................................................... 49 ENGINE COOLING SYSTEM....................................................................... 51 Maintenance Platform.................................................................... 51 Cleaning................................................................................ 51 Checking And Adding Coolant............................................................. 54 Removing And Replacing Coolant.......................................................... 55 FUEL SYSTEM................................................................................. 57 Fuel Specifications..................................................................... 57 Biodiesel Blend Fuel.................................................................... 57 Filling The Fuel Tank................................................................... 58 Removing Water From Main Fuel Filter.................................................... 59 Replacing Fuel Pre-Filter............................................................... 59 Replacing Main Fuel Filter.............................................................. 60 ENGINE LUBRICATION SYSTEM................................................................... 63 Checking And Adding Engine Oil.......................................................... 63 Engine Oil Chart........................................................................ 63 Removing And Replacing Oil And Filter................................................... 64 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................. 67 Checking And Adding Fluid............................................................... 67 Hydraulic / Hydrostatic Fluid Chart..................................................... 67 Removing And Replacing Hydraulic Fluid.................................................. 68 Removing And Replacing Hydraulic / Hydrostatic Filter................................... 70 Removing And Replacing Hydraulic Charge Filter.......................................... 71 Replacing Reservoir Breather Cap........................................................ 72 BOB-TACH (HAND LEVER)....................................................................... 73 Inspection And Maintenance.............................................................. 73 BOB-TACH (POWER)............................................................................ 75 Inspection And Maintenance.............................................................. 75 LUBRICATING THE LOADER...................................................................... 77 Lubrication Locations................................................................... 77 Track Roller And Idler Lubrication...................................................... 80 PIVOT PINS.................................................................................. 81 Inspection And Maintenance.............................................................. 81 LOADER STORAGE AND RETURN TO SERVICE........................................................ 83 Storage................................................................................. 83 Return To Service....................................................................... 83 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................. 85 Procedure............................................................................... 85 EMERGENCY EXIT.............................................................................. 87 Rear Window Identification.............................................................. 87 Rear Window Removal (Latches)........................................................... 87 Rear Window Removal (Rubber Cord)....................................................... 88 External Access (Rear Window With Latches).............................................. 88 External Access (Rear Window With Rubber Cord).......................................... 89 Front Door.............................................................................. 90 SEAT BELT................................................................................... 93 Inspection And Maintenance.............................................................. 93 HYDRAULIC SYSTEM................................................................................ 95 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 99 HYDRAULIC SYSTEM INFORMATION................................................................107 Glossary Of Hydraulic / Hydrostatic Symbols.............................................107 Troubleshooting.........................................................................111 CYLINDER (LIFT).............................................................................113 Testing.................................................................................113 Removal And Installation................................................................114 Parts Identification....................................................................118 Disassembly.............................................................................119 Assembly................................................................................121 CYLINDER (TILT).............................................................................125 Testing.................................................................................125 Removal And Installation................................................................126 Base End Pivot Pin Removal And Installation.............................................127 Parts Identification....................................................................128 Disassembly.............................................................................129 Assembly................................................................................131 CYLINDER (BOB-TACH).........................................................................135 Testing.................................................................................135 Removal And Installation................................................................136 Parts Identification....................................................................137 Disassembly.............................................................................138 Assembly................................................................................140 MAIN RELIEF VALVE...........................................................................143 Description.............................................................................143 Testing.................................................................................144 Adjusting...............................................................................146 Removal And Installation................................................................147 HYDRAULIC CONTROL VALVE (STANDARD)..........................................................149 Description.............................................................................149 Removal And Installation................................................................150 Mount Bracket Removal And Installation..................................................153 Identification Chart....................................................................154 Lift Load Check Valve Removal And Installation..........................................155 Load Check Valve Removal And Installation (Tilt And Auxiliary)..........................156 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................157 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........157 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........158 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............158 Port Relief Valve Removal And Installation..............................................159 Plug Removal And Installation...........................................................161 Rubber Boot Removal And Installation....................................................162 End Cap Block Removal And Installation..................................................162 Lift Spool And Detent Removal And Installation..........................................163 Tilt Spool Removal And Installation.....................................................171 Auxiliary Spool Removal And Installation................................................173 Auxiliary Solenoid Removal And Installation.............................................174 Solenoid Removal And Installation.......................................................175 Lock Valve Removal And Installation.....................................................176 Lift Arm Bypass Orifice Removal And Installation........................................178 Main Relief Valve Removal And Installation..............................................178 Check Valve Removal And Installation....................................................179 HYDRAULIC CONTROL VALVE (SJC)...............................................................181 Description.............................................................................181 Removal And Installation................................................................181 Actuator Removal And Installation (In Loader)...........................................185 Actuator Removal And Installation (Out Of Loader).......................................187 Identification Chart....................................................................190 Mount Bracket Removal And Installation..................................................191 Lift Load Check Valve Removal And Installation..........................................191 Load Check Valve Removal And Installation (Tilt And Auxiliary)..........................192 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................193 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........193 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........194 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............194 Port Relief Valve Removal And Installation..............................................195 Plug Removal And Installation...........................................................197 End Cap Block Removal And Installation..................................................198 Lift Spool Removal And Installation.....................................................198 Lift Spool Disassembly And Assembly.....................................................200 Tilt Spool Removal And Installation.....................................................201 Auxiliary Spool Removal And Installation................................................203 Auxiliary Solenoid Removal And Installation.............................................204 Solenoid Removal And Installation.......................................................205 Lock Valve Removal And Installation.....................................................206 Lift Arm Bypass Orifice Removal And Installation........................................208 Main Relief Valve Removal And Installation..............................................208 Check Valve Removal And Installation....................................................209 LIFT ARM BYPASS CONTROL VALVE...............................................................211 Description.............................................................................211 Testing.................................................................................211 Removal And Installation................................................................212 Bracket Removal And Installation........................................................213 Disassembly And Assembly................................................................213 HYDRAULIC PUMP..............................................................................215 Description.............................................................................215 Pump Test At Quick Couplers.............................................................216 Direct Pump Test (Standard Section).....................................................218 Direct Pump Test (Charge Section).......................................................220 Removal And Installation................................................................222 Hydraulic Pump Startup..................................................................224 Parts Identification....................................................................225 Disassembly And Assembly................................................................226 HYDRAULIC PUMP (HIGH FLOW)..................................................................227 Description.............................................................................227 Pump Test At Quick Couplers.............................................................228 Direct Pump Test (Standard Section).....................................................230 Direct Pump Test (Charge Section).......................................................231 Direct Pump Test (High Flow Section)....................................................233 High Flow Relief Valve Adjustment.......................................................235 High Flow Relief Valve Removal And Installation.........................................236 Solenoid Removal And Installation.......................................................237 Removal And Installation................................................................238 Hydraulic Pump Startup..................................................................240 Parts Identification....................................................................241 Disassembly And Assembly................................................................242 HYDRAULIC / HYDROSTATIC FILTERS.............................................................243 Description.............................................................................243 Housing Removal And Installation........................................................243 HYDRAULIC FLUID RESERVOIR...................................................................245 Description.............................................................................245 Removal And Installation................................................................245 Hydraulic Fluid Screen..................................................................246 OIL COOLER..................................................................................247 Description.............................................................................247 Removal And Installation................................................................247 BUCKET POSITION VALVE.......................................................................249 Description.............................................................................249 Removal And Installation................................................................249 Solenoid Testing........................................................................250 Disassembly And Assembly................................................................251 REAR AUXILIARY DIVERTER VALVE...............................................................253 Description.............................................................................253 Solenoid Testing........................................................................253 Removal And Installation................................................................254 Disassembly And Assembly................................................................255 BOB-TACH (POWER) BLOCK......................................................................261 Description.............................................................................261 Testing Relief Valve....................................................................262 Removal And Installation................................................................264 Disassembly And Assembly................................................................266 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................271 Description.............................................................................271 Removal And Installation................................................................271 Disassembly And Assembly................................................................272 AUTOMATIC RIDE CONTROL......................................................................275 Description.............................................................................275 Removal And Installation................................................................275 Checking The Pressure In The Accumulator................................................277 Adding Nitrogen To The Accumulator......................................................279 HYDROSTATIC SYSTEM..............................................................................281 HYDROSTATIC SYSTEM INFORMATION..............................................................283 Description.............................................................................283 Troubleshooting.........................................................................284 HYDROSTATIC DRIVE MOTOR.....................................................................285 Description.............................................................................285 Removing And Replacing Fluid............................................................286 Removal And Installation................................................................287 Parts Identification (MCR5T) (One-Speed)................................................289 Parts Identification (MCR6T) (Two-Speed)................................................290 Disassembly And Assembly................................................................291 CHARGE PRESSURE.............................................................................301 Description.............................................................................301 Testing.................................................................................302 Adjusting...............................................................................304 Sender Removal And Installation.........................................................306 HYDROSTATIC PUMP............................................................................307 Description.............................................................................307 Removal And Installation................................................................308 Hydrostatic Pump Startup................................................................309 Replenishing / High Pressure Relief Valve Removal And Installation......................310 Parts Identification (Left Half)........................................................311 Parts Identification (Right Half).......................................................312 Disassembly.............................................................................313 Assembly................................................................................320 HYDROSTATIC PUMP (SJC)......................................................................327 Description.............................................................................327 Port Locations And Gauge Installation...................................................328 Removal And Installation................................................................329 Hydrostatic Pump Startup................................................................331 Parts Identification....................................................................332 High Pressure Relief And Bypass Valve...................................................335 Charge Pressure Relief Valve............................................................336 Disassembly And Assembly................................................................337 Mechanical Neutral Adjustment...........................................................349 Hydraulic Controller Neutral Adjustment.................................................351 DRIVE BELT..................................................................................353 Belt Adjustment.........................................................................353 Stop Adjustment.........................................................................353 Belt Replacement........................................................................354 Tensioner Pulley Removal And Installation...............................................356 Tensioner Pulley Disassembly And Assembly...............................................356 TWO-SPEED / BRAKE VALVE.....................................................................359 Description.............................................................................359 Valve Block Removal And Installation....................................................360 Valve Block Disassembly And Assembly....................................................362 DRAIN MANIFOLD..............................................................................365 Description.............................................................................365 Drain Manifold Removal And Installation.................................................365 DRIVE SYSTEM....................................................................................367 BRAKE.......................................................................................369 Description.............................................................................369 Block Removal And Installation..........................................................369 Block Disassembly And Assembly..........................................................371 TRACK UNDERCARRIAGE COMPONENTS..............................................................373 Description.............................................................................373 Checking................................................................................375 Adjusting...............................................................................376 Track Removal And Installation..........................................................377 Idler (Front) Removal And Installation..................................................380 Track Tensioner Removal And Installation................................................381 Track Tensioner Disassembly And Assembly................................................382 Idler (Rear) Removal And Installation...................................................384 Roller Removal And Installation.........................................................384 Sprocket Removal And Installation.......................................................385 TRACK MAINTENANCE...........................................................................387 Track Damage Identification.............................................................387 MAINFRAME.......................................................................................399 SEAT BAR....................................................................................403 Description.............................................................................403 Removal And Installation................................................................403 Disassembly And Assembly................................................................404 Compression Spring Disassembly And Assembly.............................................405 OPERATOR CAB................................................................................407 Gas Spring Removal And Installation.....................................................407 Gas Spring Bracket Disassembly And Assembly.............................................408 Removal And Installation................................................................408 OPERATOR SEAT (SUSPENSION)..................................................................411 Removal And Installation................................................................411 Slide Rail Removal And Installation.....................................................411 Seat Belt Removal And Installation......................................................412 Lower Cushion Removal...................................................................412 Lower Cushion Installation..............................................................413 Back Cushion Removal And Installation...................................................413 Shock Removal And Installation..........................................................414 3-Point Seat Belt Removal And Installation..............................................414 BOB-TACH (HAND LEVER).......................................................................417 Description.............................................................................417 Removal And Installation................................................................417 Lever And Wedge Disassembly And Assembly................................................420 Pivot Pin Bushing And Seal Removal And Installation.....................................422 BOB-TACH (POWER)............................................................................423 Description.............................................................................423 Removal And Installation................................................................423 Lever And Wedge Disassembly And Assembly................................................426 Pivot Pin Bushing And Seal Removal And Installation.....................................428 LIFT ARMS...................................................................................429 Stabilizer Bar Removal And Installation.................................................429 Link Removal And Installation...........................................................430 Removal And Installation................................................................431 REAR GRILLE.................................................................................435 Removing................................................................................435 Installing..............................................................................435 Shield Removal And Installation.........................................................436 REAR DOOR (TAILGATE)........................................................................437 Removal And Installation................................................................437 Striker Removal And Installation........................................................438 Striker Disassembly And Assembly........................................................438 Striker (Adjusting).....................................................................439 Latch Removal And Installation..........................................................440 FUEL TANK...................................................................................441 Removal And Installation................................................................441 Fuel Level Sender Removal And Installation..............................................442 CONTROL PEDALS AND LINKAGES.................................................................443 Description.............................................................................443 Pedal Removal And Installation..........................................................443 Linkage Removal And Installation........................................................444 Pedal (Adjusting).......................................................................445 Floor Pan Removal And Installation......................................................446 CONTROL PANEL...............................................................................447 Description.............................................................................447 Removal And Installation................................................................448 Disassembly And Assembly................................................................449 Linkage Removal And Installation........................................................454 Pintle Arm Disassembly And Assembly.....................................................457 Linkage Neutral (Adjusting).............................................................458 Linkage Travel (Adjusting)..............................................................462 Shock Removal And Installation..........................................................466 CONTROL PANEL (SJC).........................................................................467 Description.............................................................................467 Removal And Installation................................................................468 CONTROL HANDLE / LEVER......................................................................469 Description.............................................................................469 Lever Removal And Installation..........................................................470 Boot Removal And Installation...........................................................470 CONTROL HANDLE / LEVER (SJC)................................................................471 Description.............................................................................471 Joystick Testing........................................................................471 Joystick Removal And Installation.......................................................472 ACCESS PANEL (INSIDE).......................................................................473 Removal And Installation (Left).........................................................473 Removal And Installation (Right)........................................................473 ACCESS PANEL (INSIDE) (SJC).................................................................475 Removal And Installation (Left).........................................................475 Removal And Installation (Right)........................................................475 WINDOW (REAR)...............................................................................477 Rear Window Identification..............................................................477 Removal And Installation (Latches)......................................................477 Disassembly And Assembly (Latches)......................................................478 Removal (Rubber Cord)...................................................................479 Installation (Rubber Cord)..............................................................480 WINDOW (TOP)................................................................................483 Removal And Installation................................................................483 WINDOW (SIDE)...............................................................................485 Removal And Installation................................................................485 CAB DOOR....................................................................................487 Description.............................................................................487 Removal And Installation................................................................487 Disassembly And Assembly................................................................488 Aligning................................................................................489 Adjusting...............................................................................490 Checking Operation......................................................................490 ARMREST.....................................................................................491 Description.............................................................................491 Removal And Installation................................................................492 Disassembly And Assembly................................................................493 LEFT SIDE LOWER PANEL.......................................................................495 Removal And Installation................................................................495 Disassembly And Assembly................................................................497 RIGHT SIDE LOWER PANEL......................................................................499 Removal And Installation................................................................499 Disassembly And Assembly................................................................500 HEADLINER...................................................................................503 Removal And Installation................................................................503 FAN DUCT PANELS.............................................................................505 Removal And Installation................................................................505 ELECTRICAL SYSTEM...............................................................................507 ELECTRICAL SCHEMATICS.......................................................................511 ELECTRICAL SYSTEM INFORMATION...............................................................551 Glossary Of Electrical Symbols..........................................................551 Standard Cab Harness Connectors.........................................................554 Deluxe Cab Harness Connectors...........................................................555 Mainframe Harness Connectors............................................................556 Description.............................................................................557 Troubleshooting.........................................................................558 Fuse And Relay Location / Identification................................................559 Solenoid Testing........................................................................562 BATTERY.....................................................................................563 Removal And Installation................................................................563 Battery Maintenance.....................................................................564 Maintaining Battery Charge Level........................................................564 Battery Service During Machine Storage..................................................564 Battery Testing.........................................................................565 Battery Charging........................................................................565 Using A Booster Battery (Jump Starting).................................................566 ALTERNATOR..................................................................................567 Belt Adjustment.........................................................................567 Belt Replacement........................................................................567 Charging System Inspection..............................................................568 Alternator Voltage Testing..............................................................569 Low Voltage Testing.....................................................................569 High Voltage Testing....................................................................570 Removal And Installation................................................................571 Parts Identification....................................................................573 STARTER.....................................................................................575 Testing.................................................................................575 Removal And Installation................................................................575 Parts Identification....................................................................576 INSTRUMENT PANEL IDENTIFICATION.............................................................577 Overview................................................................................577 Left Panel..............................................................................578 Display Screen..........................................................................580 Right Panel.............................................................................581 Left Switch Panel.......................................................................583 Right Switch Panel......................................................................583 Left Side Lower Panel...................................................................584 Right Side Lower Panel..................................................................584 Left Panel Removal And Installation.....................................................585 Right Panel Removal And Installation....................................................585 Key Switch Disassembly And Assembly.....................................................586 Alarm Disassembly And Assembly..........................................................586 Left Switch Panel Removal And Installation..............................................587 Right Switch Panel Removal And Installation.............................................587 LIGHTS......................................................................................589 Front Removal And Installation..........................................................589 Rear Removal And Installation...........................................................590 Cab Light Removal And Installation......................................................590 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)..................................................591 Description.............................................................................591 Connector Identification................................................................592 Removal And Installation................................................................598 BOBCAT CONTROLLER (SJC) (DRIVE).............................................................599 Description.............................................................................599 Connector Identification................................................................600 Removal And Installation................................................................602 ENGINE CONTROL UNIT (ECU)...................................................................603 Description.............................................................................603 Cleaning................................................................................604 Removal And Installation................................................................605 DIAGNOSTIC SERVICE CODES....................................................................607 Viewing Service Codes...................................................................607 Service Codes List......................................................................608 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™).....................................................623 Description.............................................................................623 Inspecting The BICS™ (Engine STOPPED - Key ON)..........................................624 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....624 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................624 Inspecting The Traction Lock And Parking Brake (Engine RUNNING).........................624 Inspecting The Lift Arm Bypass Control..................................................624 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)........................624 Troubleshooting.........................................................................625 SEAT BAR SENSOR.............................................................................627 Description.............................................................................627 Troubleshooting.........................................................................627 Testing.................................................................................628 Removal.................................................................................629 Installation............................................................................631 Bobcat Interlock Control System (BICS™) Circuit Test....................................632 TRACTION LOCK...............................................................................635 Description.............................................................................635 Troubleshooting.........................................................................636 Inspecting..............................................................................637 ELECTRICAL / HYDRAULIC CONTROLS (MANUAL)....................................................639 Identification Chart....................................................................639 Description.............................................................................640 Identification Chart ACD Group 0........................................................641 Identification Chart ACD Group 1........................................................642 Identification Chart ACD Group 2........................................................643 Identification Chart ACD Group 3........................................................644 ELECTRICAL / HYDRAULIC CONTROLS (SJC).......................................................645 Identification Chart....................................................................645 Description.............................................................................646 Identification Chart ACD Group 0........................................................647 Identification Chart ACD Group 1........................................................648 Identification Chart ACD Group 2........................................................649 Identification Chart ACD Group 3........................................................650 SERVICE PC (LAPTOP COMPUTER)................................................................651 Connecting Remote Start Tool (Service Tool).............................................651 CALIBRATION.................................................................................653 Description.............................................................................653 Actuator Testing........................................................................653 Lift And Tilt Calibration (SJC).........................................................656 Hydrostatic Pump Calibration (SJC)......................................................658 STEERING DRIFT COMPENSATION (OPERATOR MODE).................................................663 Description.............................................................................663 Operation...............................................................................663 STEERING DRIFT COMPENSATION (SERVICE MODE)..................................................665 Description.............................................................................665 Operation...............................................................................665 CONTROL PANEL SETUP.........................................................................667 Right Panel Setup (Deluxe Instrumentation Panel)........................................667 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...............................................671 Password Description....................................................................671 Changing The Owner Password.............................................................671 Changing The User Passwords.............................................................672 Password Lockout Feature................................................................672 MAINTENANCE CLOCK...........................................................................673 Description.............................................................................673 Setup...................................................................................674 Reset...................................................................................674 BACK-UP ALARM SYSTEM........................................................................675 Description.............................................................................675 Inspecting..............................................................................675 Adjusting Switch Position...............................................................676 Troubleshooting (Standard)..............................................................677 Troubleshooting (Joystick)..............................................................678 Alarm Removal And Installation..........................................................679 Switch Removal And Installation.........................................................679 FRONT HORN..................................................................................681 Removal And Installation................................................................681 Troubleshooting.........................................................................682 Troubleshooting (Joystick)..............................................................683 ENGINE SPEED CONTROL (HAND).................................................................685 Removal And Installation................................................................685 ENGINE SPEED CONTROL (FOOT).................................................................687 Removal And Installation................................................................687 Disassembly And Assembly................................................................688 Foot Throttle Calibration...............................................................690 CAMSHAFT AND CRANKSHAFT POSITION SENSOR.....................................................693 Removal And Installation................................................................693 MACHINE IQ..................................................................................695 Description.............................................................................695 Removal And Installation................................................................695 Procedure...............................................................................696 ENGINE SERVICE..................................................................................697 ENGINE INFORMATION..........................................................................701 Description.............................................................................701 Specifications..........................................................................702 Sensor Location.........................................................................704 Torque Values...........................................................................709 Troubleshooting.........................................................................711 Engine Removal And Installation.........................................................713 Engine Mount Replacement................................................................721 Compression - Testing...................................................................723 Injector Signal - Testing...............................................................725 Injector Signal - Testing (In-Line).....................................................727 DIESEL PARTICULATE FILTER (DPF) SYSTEM......................................................729 Description.............................................................................729 Removal And Installation................................................................729 DPF Icons...............................................................................730 DPF Regeneration Tables.................................................................731 Automatic Regeneration Operation........................................................732 Forced Regeneration Operation...........................................................733 Forced Parked Regeneration Operation....................................................734 Inhibit Mode Operation..................................................................735 AIR CLEANER.................................................................................737 Housing Removal And Installation........................................................737 ENGINE COOLING SYSTEM.......................................................................739 Radiator / Oil Cooler Removal And Installation..........................................739 Hydraulic Fan Description...............................................................741 Reversible Hydraulic Fan Description....................................................742 Fan Duct Removal And Installation.......................................................742 Hydraulic Fan Motor Assembly Removal And Installation...................................743 Hydraulic Fan Motor Removal And Installation............................................744 Hydraulic Fan Motor Disassembly And Assembly............................................746 Blower Housing Removal And Installation.................................................754 Water Pump Removal And Installation.....................................................755 Thermostat Housing Removal And Installation.............................................756 Testing The Thermostat..................................................................757 LUBRICATION SYSTEM..........................................................................759 Description.............................................................................759 Oil Pan Removal And Installation........................................................760 Oil Pump Removal And Installation.......................................................761 Oil Pump Relief Valve Description.......................................................762 Oil Pump Relief Valve Removal And Installation..........................................762 Oil Cooler Removal And Installation.....................................................763 Oil Filter Head Removal And Installation................................................764 Oil Cooler Bypass Description...........................................................765 Oil Cooler Bypass Removal And Installation..............................................765 FUEL SYSTEM.................................................................................767 Description.............................................................................767 Fuel Filter Housing Removal And Installation............................................768 Fuel Lift Pump Removal And Installation.................................................770 Transfer Pump / High Pressure Pump Removal And Installation.............................770 Fuel Temperature Sensor Removal And Installation........................................772 Fuel Cooler Removal And Installation....................................................773 Fuel Recirculation Valve (FRV) Removal And Installation.................................773 Fuel Injector Removal And Installation..................................................774 Injector Coding.........................................................................776 CYLINDER HEAD...............................................................................777 Glow Plugs Testing......................................................................777 Glow Plug Removal And Installation......................................................778 Cylinder Head Removal And Installation..................................................779 Cylinder Head Disassembly And Assembly..................................................784 Cylinder Head Inspection................................................................785 Cylinder Head Top Clearance.............................................................786 Valve Step Height.......................................................................787 Valve Stem Height.......................................................................787 Valve Guide.............................................................................788 Valve...................................................................................788 Valve Spring............................................................................789 Rocker Arm Shaft Disassembly And Assembly...............................................790 Rocker Arm Shaft Inspection.............................................................791 Push Rod Inspection.....................................................................791 CRANKSHAFT AND PISTONS......................................................................793 Piston And Connecting Rod Removal And Installation......................................793 Piston And Connecting Rod Inspection....................................................794 Crankshaft Removal And Installation.....................................................796 Cylinder Block Inspection...............................................................799 Crankshaft Inspection...................................................................801 Connecting Rod Inspection...............................................................801 Engine Component Class..................................................................802 CAMSHAFT....................................................................................805 Removal And Installation................................................................805 Inspecting..............................................................................806 GEARCASE....................................................................................809 Gearcase Cover Removal And Installation.................................................809 Gear Backlash...........................................................................810 Gear Timing.............................................................................811 Idle Gear Removal And Installation......................................................812 Idle Gear Inspection....................................................................812 TURBOCHARGER................................................................................813 Description.............................................................................813 Removal And Installation................................................................813 Inspection..............................................................................816 FLYWHEEL AND HOUSING........................................................................817 Flywheel Removal And Installation.......................................................817 Ring Gear Removal And Installation......................................................818 Housing Removal And Installation........................................................818 EXHAUST GAS RECIRCULATION (EGR) SYSTEM......................................................819 Description.............................................................................819 Removal And Installation................................................................820 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)................................................823 AIR CONDITIONING SYSTEM FLOW................................................................825 Description.............................................................................825 Chart...................................................................................826 Components..............................................................................827 Safety Equipment........................................................................830 REGULAR MAINTENANCE.........................................................................831 Filters.................................................................................831 Belt Adjustment.........................................................................832 Belt Replacement........................................................................832 Air Conditioning Condenser..............................................................832 Air Conditioning Lubrication............................................................832 Air Conditioning Service Chart..........................................................833 Evaporator / Heater Coil................................................................834 TROUBLESHOOTING.............................................................................837 Blower Motor Does Not Operate...........................................................837 Blower Motor Operates Normally, But Air Flow Is Insufficient............................837 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............837 The Compressor Does Not Operate At All, Or Operates Improperly..........................837 Gauge Pressure Related Troubleshooting..................................................838 Troubleshooting Tree....................................................................840 Temperature / Pressure Chart............................................................844 Poor A/C Performance....................................................................846 HVAC Repair And Leaks...................................................................847 Electrical System.......................................................................848 Engine Coolant Bypassing The Heater Valve...............................................854 Heater Valve Not Opening Or Closing.....................................................855 SYSTEM CHARGING AND RECLAMATION.............................................................857 Refrigerant Identification..............................................................857 Reclamation And Charging With Recovery / Charging Unit..................................858 COMPRESSOR..................................................................................861 Removal And Installation................................................................861 Oil.....................................................................................863 Oil Check...............................................................................864 CONDENSER...................................................................................867 Removal And Installation................................................................867 RECEIVER / DRIER............................................................................869 Receiver / Drier Removal And Installation...............................................869 Pressure Switch Removal And Installation................................................871 Schrader® Valve Removal And Installation................................................872 EVAPORATOR / HEATER UNIT....................................................................873 Removal And Installation................................................................873 THERMOSTAT..................................................................................875 Description.............................................................................875 Removal And Installation................................................................876 EXPANSION VALVE.............................................................................877 Removal And Installation................................................................877 EVAPORATOR COIL.............................................................................879 Removal And Installation................................................................879 HEATER COIL.................................................................................881 Removal And Installation................................................................881 BLOWER FAN..................................................................................883 Removal And Installation................................................................883 Disassembly And Assembly................................................................883 HEATER VALVE................................................................................887 Removal And Installation................................................................887 EVAPORATOR / HEATER COVER...................................................................889 Removing................................................................................889 Installing..............................................................................889 SPECIFICATIONS..................................................................................891 LOADER SPECIFICATIONS.......................................................................893 Machine Dimensions......................................................................893 Performance.............................................................................894 Engine..................................................................................894 Drive System............................................................................895 Controls................................................................................895 Hydraulic System........................................................................896 Electrical System.......................................................................897 Capacities..............................................................................897 Tracks..................................................................................898 Ground Pressure.........................................................................898 Environmental...........................................................................898 Temperature Range.......................................................................898 TECHINCAL SERVICE GUIDE SPECIFICATIONS......................................................899 Engine..................................................................................899 Engine Torques..........................................................................899 Cooling System..........................................................................899 Loader Torques..........................................................................900 Hydraulic / Hydrostatic System..........................................................900 Fuel Consumption........................................................................900 TORQUE SPECIFICATIONS FOR BOLTS.............................................................901 Torque For General SAE Bolts............................................................901 Torque For General Metric Bolts.........................................................902 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................903 Straight Thread O-ring Fitting..........................................................903 Flare Fitting...........................................................................904 Tubelines And Hoses.....................................................................904 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................905 Specifications..........................................................................905 CONVERSIONS.................................................................................907 Decimal And Millimeter Equivalent Chart.................................................907 U.S. To Metric Conversion Chart.........................................................907 SERVICE TOOLS REQUIRED......................................................................909 Remote Start Tools......................................................................909 Hydraulic Tools.........................................................................910 Mainframe And Drive Tools...............................................................913 Electrical Tools........................................................................916 Engine Tools............................................................................917 HVAC Tools..............................................................................922 ALPHABETICAL INDEX..............................................................................923
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