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Bobcat T590 Troubleshooting

The Bobcat T590 compact track loader is powered by 158.7 cu.in (2.6L) Kubota V2607-DI-TE3-B 4-cylinder turbocharged liquid-cooled diesel engine with a rated power of 61 hp (45.5 kW). The Bobcat T590 is equipped with a single-speed or two-speed hydrostatic transmission, hydraulic disc brakes, and rubber tracks with steel inserts. The hydraulic system has a pump with fluid flow rate of 17.1 gpm (64.7 lpm). The hydraulic pressure is 3550 psi (245 bar). The compact track loader has a rated operating capacity of 2110 lbs (955 kg) and tipping load of 6025 lbs (2730 kg). The boom lifting force is 4755 lbs (2155 kg), and bucket breakout force is 4490 lbs (2035 kg).

Engine Troubleshooting

Engine hard to start or will not start
Air in fuel system - Bleed fuel system.
Fuel filter element is clogged - Change filter element.
Burnt or defective injection nozzle - Change fuel injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is not correct - Need to adjust valve clearance.
Fuel injection pump is not operating properly - Replace injection pump or repair it.

Diesel starts and stalls immediately
Air filter is dirty - Install new air filter element.
Fuel filter element is dirty - Clean the filter or install new filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Fuel injectors are faulty or clogged - Clean or replace fuel injectors.
Fuel injection pump is damaged - Install a new pump or rebuild.

Engine stalls while running
Engine not warmed up - Normalize the temperature by warming up the engine.
Fuel filter plugging - Service or replace the filter.
There is air in the fuel system - Bleed the system.
Fuel injection nozzles are faulty or clogged - Install a new kit of correctly balanced nozzles.
Improper fuel injection timing - Check the fuel injection pump timing adjustment.

Engine stops when idle
Too low idle RPM - Need to adjust idle speed.
Fuel injection pump is faulty - Repair or install a new fuel pump.
Damaged or clogged injectors - Replace or clean fuel injectors.
Incorrect valve clearance - Check and adjust.

Diesel engine is losing power
Clogged air filter - Clean or replace element.
Defective injection nozzle - Service or change injection nozzles.
Incorrect fuel injection pressure - Correct the pressure settings.
Valve clearance is not correct - Adjustment procedure required.
Low idle speed set incorrectly - Test and adjust.
Fuel lines or hoses are clogged - Fuel hoses and lines must be clean.
Cylinder head gasket is worn - Replace cylinder head gasket.
Piston rings are defective or leaking - Piston rings need to be replaced.

Engine overheating
Insufficient coolant fluid - Fill radiator to proper level and check components for faults.
Engine oil level low - Fill up the oil to required level.
Clogged radiator core or leaking radiator cap - Replace cap or clean radiator.
Fan belt is loose or defective - Belt replacement is recommended.
Engine is overloaded - Reduce engine load.

Low oil pressure
Low oil level - Add oil to the engine crankcase.
Oil filter element clogging - Service or replace engine oil filter.
Different type of engine oil - Fill up with the proper oil viscosity.
Excessive oil clearance of crankshaft bearing - Bearing replacement required.
Oil pump failure - Remove and inspect oil pump.

Engine knocking or noise
Engine oil level is insufficient - Checking oil level and add if necessary.
Engine is not fully warmed up - Warm up engine as required.
Improper setting of fuel injection pump timing - Adjust as recommended.
Low idle speed setting is not correct - Normalize low idle speed.
Damaged or clogged injectors - Clean or replace fuel injectors.
Connecting rod is misaligned or defective - Align or replace connecting rod.
Broken or worn pistons - Replace the pistons as required.

Drive System Troubleshooting

Machine will not move forward or backward
Hydraulic oil is insufficient - Check and refill the hydraulic oil.
Jammed or damaged undercarriage tracks - Remove jamming or repair tracks.
Relief valve is not working correctly - Repair or change.
Hydraulic filter or suction line is dirty - Check, clean, or replace if required.
Foot or hand controls are defective - Check and repair as required.
Defective drive pump or motor - Inspect and change as required.

Machine does not move straight or moves jerky
Track mechanism is jammed or defective - Remove jamming or repair tracks.
Sagging or worn tracks - Repair tracks or correct track sag with tension.
Debris, dirt, or foreign objects jammed in undercarriage track frame - Remove debris and clean track frame.

Low power
Plugged hydraulic oil filter - Check, clean, or change as necessary.
Relief valve is damaged or open - Close or replace relief valve.
Transmission components are faulty or damaged - Inspect and replace faulty parts.
Damaged input drive shaft - Replace drive shaft.
Air in the hydraulic system - Need to bleed air.

Drive system overheats
Insufficient hydraulic oil - Check and refill the hydraulic oil.
Clogged hydraulic fluid filter - Check, clean, or replace as required.
Relief valve is not working correctly - Repair or change.
Drive pump or hydraulic motor malfunction - Repair or change faulty component.
Oil cooler is clogged - Clean the cooling fins.
Drive system overloaded continuously - Reduce the load.

Excessive noise
Oil viscosity is too heavy - Drain and refill with proper oil.
Air in hydraulic system - Bleed air from system.
Drive pump or hydraulic motor is damaged - Replace or repair faulty component.
Mechanical components of drive system are worn - Check drive system and change faulty components.

Hydraulics Troubleshooting

Hydraulic system has overheating
Incorrect hydraulic pressure setting - Adjust it correctly.
Misadjusted or defective main relief valve - Adjust the valve or replace if necessary.
Dirty hydraulic fluid - Fill up with fresh hydraulic fluid.
Hydraulic oil level is low - Fill up the hydraulic oil.
Hydraulic pump is worn - Repair or replace pump if necessary.

Lift arm does not lower or raise
Defective lift controls - Repair or change.
Damaged hydraulic oil pump - Replace or repair pump if necessary.
Damaged hydraulic control valve - Repair or replace the valve.
Damaged hydraulic cylinder - Repair or install a new lift cylinder.
Hydraulic oil level low - Fill the system to proper hydraulic oil level.

Bucket can't tilt
Faulty bucket tilt controls - Check and repair as required.
Defective hydraulic pump - Repair or install new hydraulic pump.
Hydraulic control valve failure - Change or repair hydraulic valve.
Bucket cylinder malfunction - Repair or replace cylinder.
Low hydraulic fluid level - Fill the system to proper hydraulic fluid level.

Bucket or lift arm runs slowly
Defective hydraulic pump - Check the pump performance and replace it if required.
Oil leaks from hydraulic cylinder - Install new cylinder seals.
Hydraulic fluid level low - Add fluid as required.
Hydraulic control valve is defective or set improper - Set correctly or repair.
Hydraulic pressure has dropped - Adjust pressure as required.

Bucket or boom is moving jerkily
Hydraulic system is leaking air - Bleed air from system.
Clogged hydraulic oil filter element - Change or clean oil filter.
Contaminated hydraulic fluid - Hydraulic fluid change required.
Cylinder tube or rod scoring - Change defective component.

Hydraulic pump is excessively noisy
Not enough oil or hydraulic system leaking - Remedy hydraulic leakage or refill oil as necessary.
Plugged hydraulic filter - Clean or replace the filter.
Suction line is clogged - Suction line needs to be cleaned.
Air enters the pump - Bleed air.
Faulty pump components - Rebuild or install new pump.

Electrical Troubleshooting

Battery is not charging
Wiring connections are loose or corroded - Service or tighten cable connections.
Electrical terminal connectors are defective - Install new terminal connectors.
Bad cell in battery - Battery replacement required.
Belt is worn or loose - Install a new belt or adjust belt tension.

Starter turns slowly
Battery power is low - Battery needs to be recharged.
Battery discharges quickly - Service or replace the battery.
Faulty battery terminals or disconnected cables - Connect wires correctly or change terminals.

Starter is not working
Battery is low or faulty - Need to charge or replace the battery.
Battery wiring is disconnected or improperly connected - Inspect wiring and connect as required.
Battery capacity is low - Battery is drained, charge it.
Starter motor is damaged - Starter needs to be replaced.