Bobcat T595 Track Loader Troubleshooting

The Bobcat T595 compact track loader is powered by 146.5 cu.in (2.4L) Bobcat Doosan D24 4-cylinder direct injection turbocharged diesel engine with a rated power of 74 hp (55.2 kW). The Bobcat T595 is equipped with one-speed or two-speed transmission, vertical-lift loader boom, solid-mounted undercarriage with triple flange rollers, and rubber tracks. 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 loader has a rated operating capacity of 2200 lbs (998 kg) and tipping load of 6285 lbs (2850 kg). The lift height is 119" (3020 mm) to hinge pin, and dump height is 91.3" (2320 mm).

Engine Troubleshooting

Engine starts hard or won't start

Air trapped in fuel system - Bleed air.
Dirty fuel filter - Service or replace the filter.
Fuel injection nozzles are damaged - Clean or replace injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
The valve clearance is incorrect - Have it adjusted.
Fuel injection pump failure - Install a new fuel pump or repair.

Engine starts but immediately stalls

Dirty air cleaner - Clean or replace element.
Clogged fuel filter - Change the filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Fuel injectors are faulty or clogged - Clean or replace fuel injectors.
Fuel injection pump malfunctioning - Rebuild or install a new injection pump.

Engine stalls while running

Low coolant temperature - Warm up the engine.
Fuel filter element is dirty - Clean the filter or install new filter element.
Air in fuel system - Bleed fuel system.
Faulty fuel injection nozzles - Check and replace nozzles if required.
Improper setting of fuel injection pump timing - Set it up as required.

Engine stops when idle

Low idle speed setting is not correct - Adjustment required.
Faulty fuel injection pump - Install a new pump or rebuild.
Defective fuel injectors - Replace or clean fuel injectors.
Valve out of adjustment - Need to adjust valve clearance.

Diesel engine loses power

Clogged air cleaner - Clean or change.
Fuel injection nozzles are damaged - Replace injection nozzles.
Insufficient fuel injection pressure - Correct the pressure settings.
Valve clearance is wrong - Check and adjust.
Incorrect low idle setting - Test and adjust.
Clogged fuel hoses or lines - Fuel hoses and lines must be clean.
Defective cylinder head gasket - Gasket should be replaced.
Piston rings are leaking or defective - Change piston rings.

Engine is overheated

Lack of engine coolant - Add coolant and check the components of cooling system.
Engine oil level is low - Need to add engine oil.
Radiator core is dirty or radiator cap is damaged - Change cap or clean radiator.
Broken or loose fan belt - Belt change is required.
Engine is overloaded - Load reducing required.

Low oil pressure

Engine oil insufficient - Add oil as required.
Oil filter is clogged - Clean or replace engine oil filter element.
Wrong oil viscosity - Fill up with the proper oil viscosity.
Incorrect oil clearance in main bearing - Bearings need to be reinstalled.
Oil pump is worn or damaged - Repair or change.

Engine knocking or noise

Engine oil level is low - Add oil to the engine crankcase.
Engine is not preheated - Warm up engine as required.
Improper fuel injection timing - Adjust as recommended.
Incorrect low idle speed adjustment - Adjust low idling as recommended.
Fuel injector fault - Inspect fuel injectors and change as required.
Connecting rod is not aligned or worn - Align or replace connecting rod.
Pistons are worn or broken - Pistons replacement required.

Drive System Troubleshooting

Drive system doesn't work in either direction

Low hydraulic oil level - Fill the system to proper hydraulic oil level.
Blocked or defective undercarriage tracks - Remove blockage or repair tracks.
Relief valve defective or worn - Rebuild or install a new relief valve.
Suction line or hydraulic filter is clogged - Check, clean, or replace if required.
Defective hand or foot controls - Check and repair as required.
Drive motor or pump is defective - Inspect and change as required.

Machine won't drive straight or drives jerkily

Track mechanism is jammed or defective - Repair or remove jamming.
Tracks are faulty or improperly tensioned - Adjust track tension or replace tracks.
Track frame is blocked with debris, dirt, or foreign objects - Remove debris or foreign objects and clean track frame.

Low power

Hydraulic oil filter is dirty - Check, clean, or change as necessary.
Relief valve is damaged or open - Change or close relief valve.
Transmission components are worn or defective - Check and change defective components.
Stuck input drive shaft - Rebuild or change the shaft.
Air in hydraulic system - Air bleeding is required.

Drive system overheats

Low hydraulic oil level - Fill the system to proper hydraulic oil level.
Hydraulic fluid filter is clogged - Check, clean, or replace as required.
Relief valve is worn or damaged - Change or repair defective relief valve.
Defective drive pump or hydraulic motor - Repair or change faulty component.
Plugged hydraulic oil cooler - Cooling fins should be cleaned.
Drive system is overloaded - Reduce loading.

Drive system is excessively noisy

Incorrect oil viscosity - Use correct oil viscosity.
Air leaks in hydraulic system - Air bleeding is required.
Drive pump or hydraulic motor is damaged - Inspect and change as required.
Defective or worn mechanical parts of drive system - Check drive system and change faulty parts.

Hydraulics Troubleshooting

Hydraulic system is overheated

Hydraulic pressure is not correct - Correct setting is required.
Main relief valve is defective or unadjusted - Adjust relief valve or change if required.
Dirty hydraulic oil - Fill up with fresh hydraulic oil.
Lack of hydraulic fluid - Add fluid to the hydraulic system.
Faulty hydraulic oil pump - Repair or change pump if required.

Lift arm fails to drop or lift

Defective lift controls - Change or repair.
Damaged hydraulic oil pump - Repair or change pump if required.
Hydraulic control valve is faulty - Repair or replace hydraulic valve.
Hydraulic cylinder failure - Repair or change hydraulic cylinder.
Hydraulic oil is insufficient - Need to add oil.

Bucket does not tilt

Bucket controls failure - Repair or change.
Defective hydraulic pump - Replace or repair pump if necessary.
Damaged hydraulic control valve - Install a new valve or repair it.
Bucket cylinder failure - Change or repair cylinder.
Hydraulic fluid is insufficient - Add fluid as required.

Boom or bucket runs slowly

Worn hydraulic oil pump - Test the pump flow rate and install new pump if required.
Oil leaks from hydraulic cylinder - Repair leak by replacing the seals.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.
Hydraulic control valve is faulty or out of adjustment - Adjust correctly or repair.
Hydraulic pressure loss - Adjust pressure correctly.

Bucket or boom jerks when working

Air in hydraulic system - Need to bleed air.
Hydraulic oil filter is clogged - Clean or replace the filter.
Contaminated hydraulic fluid - Fill up with fresh hydraulic fluid.
Cylinder tube or rod is scored - Replace defective component.

Hydraulic pump makes excessive noise

Insufficient oil level or leaking hydraulic system - Add hydraulic oil or correct system leaks.
Hydraulic filter clogging - Service or change hydraulic filter.
Suction line clogging - Suction line must be serviced.
Air trapped in hydraulic pump - Remove air from hydraulics.
Pump components are worn out - Change or rebuild pump.

Electrical Troubleshooting

Battery does not charge

Loose or corroded wire connections - Tighten or service connections.
Electrical terminal connectors are defective - Terminal connectors should be replaced.
Battery failing - Replace the battery.
Belt is defective or loose - Replace belt or adjust belt tension.

Starter motor turns slow

Battery power is low - Charge the battery.
Battery is draining quickly - Service or replace the battery.
Disconnected wires or corroded battery terminals - Check cable connections and change or clean terminals.

Starter will not crank

Battery is drained or worn - Charge or replace the battery.
Wire harness is disconnected or incorrectly connected - Check wire harness and connect as required.
Low battery output voltage - Recharge the battery.
Defective starter motor - Starter should be replaced.