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Bobcat S595 Troubleshooting

The Bobcat S595 skid steer loader is powered by 146.5 cu.in (2.4L) Bobcat Doosan D24 four-cylinder turbocharged diesel engine with a rated power of 74 hp (55.2 kW) at 2600 rpm. The Bobcat S595 is equipped with 1-speed or 2-speed hydrostatic transmission, vertical-lift loader boom, 80 HSOC roller chains, and 10x16.5 or 31-12x16.5 tires. The hydraulic system has a pump with fluid flow rate of 17.1 gpm (64.7 lpm). The hydraulic pressure is 3500 psi (241 bar). The skid steer loader has a rated operating capacity of 2200 lbs (998 kg) and tipping load of 4400 lbs (1996 kg). The boom lifting force is 4796 lbs (2180 kg), and bucket breakout force is 5620 lbs (2554 kg).

Engine Troubleshooting

Engine starts hard or will not start
Air in fuel tank - Bleed fuel tank.
Clogged fuel filter - Filter maintenance required.
Clogged or defective injection nozzles - Check and replace nozzles if required.
Water in the fuel system - Change fuel and repair fuel system.
Excessive valve clearance - Adjustment procedure required.
Fuel injection pump is damaged - Change pump or rebuild it.

Engine starts and then shuts off
Plugged air filter - Install new air filter element.
Fuel filter element clogging - Change filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Fuel injectors are faulty or clogged - Test and replace fuel injectors if necessary.
Fuel injection pump is damaged - Replace injection pump or repair it.

Engine stops running suddenly
Low coolant temperature - Warm up the engine.
Fuel filter is plugged - Change the filter element.
Air trapped in fuel system - Bleed air.
Fuel injection nozzles are clogged or faulty - Test injection nozzles and change if necessary.
Wrong setting of fuel injection pump timing - Adjust according to specifications.

Engine stops at low idle speed
Incorrect low idle setting - Correct the settings.
Fuel injection pump failure - Change or repair the pump.
Clogged or defective injectors - Inspect fuel injectors and change as required.
The valve clearance is not adjusted - Check and adjust as required.

Low engine power
Dirty air cleaner - Install new air cleaner element.
Clogged or burnt injection nozzle - Replace injection nozzles.
Incorrect fuel injection pressure - Adjust to correct pressure.
The valve clearance is not adjusted - Need to adjust valve clearance.
Low idle speed setting is not correct - Correct the settings.
Fuel hoses or lines are dirty - Clean fuel system lines and hoses.
Cylinder head gasket is damaged - Install new cylinder head gasket.
Piston rings are damaged or leaking - Piston rings replacement required.

Engine is overheated
Engine coolant is insufficient - Fill the cooling system and check components for leaks or other faults.
Engine oil level low - Fill the crankcase with engine oil.
Clogged radiator core or leaking radiator cap - Clean radiator or change cap.
Fan belt slipping or worn - Belt replacement is recommended.
Engine overload - Load reducing required.

Oil pressure is insufficient
Oil level is insufficient - Fill crankcase to proper oil level.
Oil filter is clogged - Clean or change engine oil filter.
Different type of engine oil - Use proper viscosity oil.
Crankshaft bearing oil clearance is excessive - Replace bearings.
Oil pump malfunction - Repair or replace.

Abnormal engine knocking or noise
Engine oil level is insufficient - Need to add engine oil.
Engine is not preheated - Warm up the engine.
Fuel injection pump timing is not adjusted - Use the correct fuel injection pump timing adjustment.
Wrong adjustment of low idle speed - Correct low idle settings.
Fuel injector fault - Replace fuel injectors.
Misaligned or faulty connecting rod - Align or change connecting rod.
Pistons are scored or worn - Pistons replacement required.

Drive System Troubleshooting

Drive system сan't work in either direction
Hydraulic fluid level low - Add fluid as required.
Drive chain is worn - Inspect drive chain and replace defective components.
Input drive shaft is defective - Service or change drive shaft.
Stuck relief valve - Change or repair relief valve.
Hydraulic filter or suction line is plugged - Clean suction line or replace hydraulic filter.
Foot or hand controls are damaged - Check and repair as required.
Drive pump or motor is damaged - Repair or change faulty component.

Reduced power
Clogged hydraulic oil filter - Check, clean, or change as necessary.
Opened or defective relief valve - Close or replace relief valve.
Faulty or worn transmission components - Inspect and change defective parts.
Defective input drive shaft - Change or repair faulty drive shaft.
Air in hydraulic system - Need to bleed air.

Drive system keeps overheating
Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.
Hydraulic fluid filter is dirty - Replace or service hydraulic filter.
Defective relief valve - Repair or replace.
Defective drive pump or hydraulic motor - Repair or replace faulty component.
Hydraulic oil cooler is dirty - Cooling fins should be cleaned.
Overloaded drive system - Reduce drive system load.

Drive system is noisy
Improper oil viscosity - Use oil of correct viscosity.
Air in hydraulic system - Bleed air from system.
Damaged drive pump or hydraulic motor - Replace or repair faulty component.
Worn or defective mechanical components of drive system - Check drive system and change faulty components.

Hydraulics Troubleshooting

Hydraulic system is overheated
Hydraulic pressure incorrectly adjusted - Set pressure correctly.
Defective or misadjusted main relief valve - Replace or set up the relief valve.
Hydraulic fluid contamination - The fluid must be changed.
Hydraulic fluid level is low - Check and refill the hydraulic fluid.
Hydraulic pump is faulty - Change or repair hydraulic pump if required.

Boom does not raise or lower
Lift controls malfunction - Repair or change.
Hydraulic pump not working - Install new pump or repair it.
Hydraulic control valve is defective - Repair or replace the valve.
Hydraulic cylinder not working - Change or repair lift cylinder.
Low hydraulic oil level - Need to add oil.

Bucket does not function
Bucket tilt controls are defective - Check and repair as required.
Defective hydraulic pump - Repair or install new hydraulic pump.
Faulty hydraulic control valve - Change or repair hydraulic valve.
Faulty hydraulic bucket cylinder - Install a new cylinder or repair it.
Insufficient hydraulic oil - Check and refill the hydraulic oil.

Slow bucket or lift arm operation
Hydraulic pump is faulty - Flow-rate hydraulic pump and replace pump if necessary.
Oil leaks from hydraulic cylinder - Install new cylinder seals.
Hydraulic fluid level low - Add fluid as required.
Hydraulic control valve is faulty or out of adjustment - Adjust correctly or repair.
Hydraulic pressure has dropped - Correct setting is required.

Jerky operation of the bucket or boom
Air in the hydraulic system - Air bleeding is required.
Clogged hydraulic oil filter element - Change or clean oil filter.
Hydraulic fluid is contaminated - The fluid must be changed.
Scored cylinder tube or rod - Replace failed component.

Hydraulic pump is excessively noisy
Leaking hydraulic system or insufficient oil level - Correct hydraulic leaks or top up oil as needed.
Clogged hydraulic filter - Change or clean oil filter.
Dirty suction line - Suction line needs to be cleaned.
Pump sucks air - Need to bleed air.
Worn pump parts - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery is not charging
Corroded or loose wire connections - Clean or tighten wiring connections.
Battery terminal connectors are defective - Install new terminal connectors.
Battery faulty cell - Change the battery.
Worn or loose belt - Need to adjust belt tension or replace belt.

Starter turns slow
Low battery capacity - Recharge the battery.
Battery runs out quickly - Service charging system or install new battery.
Wires are disconnected or battery terminals are corroded - Check cables and clean or change terminals.

Starter doesn't crank
Battery is low or faulty - Recharge or change battery.
Wiring harness is disconnected or improperly connected - Check wiring harness and connect as required.
Battery power is low - Battery needs to be recharged.
Starter motor is damaged - Change or repair starter.