Bandit 2590 Operating & Parts Manual Download Page 53

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Bandit

MODEL 2590

Use as a reference only, locations may vary depending on options or component manufacturer.

Lubrication point instructions are described on the machine, in the Lubrication & Coolant

Section and Maintenance Section of this manual, or component manufacturer’s manual.

NOTICE

LUBRICATION CHART

MAINTENANCE

Summary of Contents for 2590

Page 1: ...el ___________ S N ______________ Copyright 6 18 ATTENTION Depending on what replacement parts you are ordering we will need the following information CHIPPER COMPONENTS Serial Number Model Number of Chipper ENGINE COMPONENTS Brand Engine Serial Number Engine Model Number CLUTCH COMPONENTS Brand Clutch Serial Number Clutch Model Number MODEL 2590 OPERATING PARTS MANUAL 6750 Millbrook Rd Remus MI 4...

Page 2: ...ngs ca gov diesel Respirar gases de escape de motores diesel le expone a quÍmicos conocidos por el estado de California como causales de cáncer y defectos congénitos u otros daños reproductivos Para mayor informaciÓn visite www P65warnings ca gov diesel Siempre encienda y opere el motor en áreas bien ventiladas Si está en un área cerrada ventile escape hacia el exterior No modiﬁque ni altere el si...

Page 3: ...s received instruction and fully understands that the operators must always be located within easy reach of all feed control and shut down devices 6 _____ The customer has received instruction and fully understands that this machine is designed to be loader fed and is to follow all feeding instructions in the manual The customer understands that under no circumstances should the operator hand feed...

Page 4: ...t as ordered ________________________________________________ 5 Did all welds appear to be high quality ______________________________________________ 6 Was the overall machine to your liking ______________________________________________ 7 What problems have you experienced ______________________________________________ 8 Have any components regularly loosened that caused problems _______________...

Page 5: ...S 13 DECALS 14 CONTROLS 21 TRANSPORTATION PROCEDURES 34 MAINTENANCE 37 HYDRAULICS 73 ELECTRICAL 84 REPLACEMENT PARTS 85 INFEED HOPPER COMPONENTS 86 BEARING COMPONENTS 95 CHIPPER COMPONENTS 88 CHIPPER KNIFE HARDWARE 92 ANVIL HARDWARE 94 DISCHARGE COMPONENTS 96 LOADER COMPONENTS 98 FRAME ACCESSORY COMPONENTS 100 FRONT STABILIZER COMPONENTS 102 FUEL TANK COMPONENTS 103 HYDRAULIC TANK COMPONENTS 105 E...

Page 6: ...ty to provide and follow a regularly scheduled preventative maintenance and repair program on the product using only factory approved replacement parts Any unapproved repairs or modifications may not only damage the machine and its performance but could result in severe personal injury Unapproved repairs or modifications will void warranty and eliminate manufacturer of any liability claims Consult...

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Page 8: ...NUMBER AND OR WORK ORDER NUMBER LOCATIONS 1 Engine Frame Right Side 2 W O on top of frame side Right Side The engine information is located on the engine block The clutch information is located on the clutch plate if equipped 2 1 SERIAL NUMBER LOCATIONS NOTICE ...

Page 9: ...cals guards and designs for your protection Don t ever take the machine for granted always be cautious and careful when operating your equipment Read and follow all the instructions in your manual thoroughly Your safety is dependent on your knowledge of how to operate and maintain this machine You may obtain additional copies of this manual from your Bandit Dealer Before operating machine you must...

Page 10: ...le for approximately 15 minutes to allow the system to warm up to operating temperature DANGER DO NOT operate this machine indoors Exhaust fumes can be fatal Never refuel while the machine is running Never refuel in the shop or building Always refuel in a well ventilated area away from sparks or open flames DO NOT SMOKE Extinguish all smoking materials Wipe up all spilled fuel before restarting th...

Page 11: ...Keep the machine in good condition Be sure the machine is in good operating condition and that all safety devices including guards and shields are installed and functioning properly Visually inspect the machine daily before starting the machine Refer to the Daily Start Up Maintenance Make no modifications to your equipment unless specifically recommended or requested by Bandit Industries Inc Avoid...

Page 12: ...ing that component Follow all OSHA instructions for lifting Before opening or closing the feedwheel trap door disengage clutch turn off engine wait for the disc drum to come to a complete stop install the disc drum lock pin disconnect battery and make sure the ignition key is in your possession In the event that dirty material is being run through the chipper the feedwheel trap door can be opened ...

Page 13: ...locking as needed DANGER CLEAN MACHINE OF ALL DEBRIS DO NOT leave this machine unattended until all potential fire debris is removed no fire or smoldering exists and hot spots are cold The engine creates many hot spots including exhaust manifold exhaust turbo if equipped etc Remove all flammable debris such as wood chips leaves oils fuels etc from engine exhaust engine turbo if equipped beside aro...

Page 14: ...m 100 FT 30 5 m 46 FT 14 m 46 30 FT 9 1 m 30 25 MAX 17 MAX The machine should never be parked on a slope at any time The machine can coast or creep causing equipment damage and or personal injury Make sure everyone is clear of machine before moving the machine Stay clear of undercarriage travel system when the machine is moving DO NOT entangle feet or hands in undercarriage travel system NEVER sit...

Page 15: ...s will vary depending on optional equipment EQUIPMENT SPECIFICATIONS EQUIPMENT SPECIFICATIONS Model 2590 Trailer Height 144 3 7 m Length 423 10 7 m Width 113 2 9 m Weight 29 000 35 000 lbs 13 154 15 876 kg Fuel Tank Capacity 200 gal 757 Liters Hydraulic Tank Capacity 85 gal 322 Liters ...

Page 16: ... become damaged replace immediately NOTICE Decal locations may vary these are general locations DECALS DECAL LOCATIONS 2590 1 2 34 38 52 3 17 22 31 40 54 58 7 24 39 48 24 9 4 7 11 12 1 2 9 11 12 14 18 24 34 14 22 49 51 55 60 52 2 25 26 33 36 38 45 47 50 17 18 60 63 64 65 68 69 1 5 8 10 12 18 23 16 19 22 24 44 47 10 24 27 28 48 55 49 50 52 57 ...

Page 17: ...4 Arrow 23 INST 10 Stabilizer Down Up 24 INST 12 Grease Daily Arrow 25 INST 44 Proposition 65 26 INST 45 For Parts and Service 27 INST 48 Disc Drum Lock Tube 28 INST 49 Disc Drum Lock Pin 29 INST 53 Hydraulic Oil Hydrex XV 30 INST 75 Hydraulic Oil For PT Tech Clutch 31 INST 90 Tongue Down Up 32 INST 91 Lubricant For Twin Disc Hydraulic Clutch 33 INST 92 Air Brake Release 34 INST 95 Electric Plug I...

Page 18: ... become damaged replace immediately NOTICE Decal locations may vary these are general locations DECALS DECAL LOCATIONS 2590 1 2 34 38 52 3 17 22 31 40 54 58 7 24 39 48 24 9 4 7 11 12 1 2 9 11 12 14 18 24 34 14 22 49 51 55 60 52 2 25 26 33 36 38 45 47 50 17 18 60 63 64 65 68 69 1 5 8 10 12 18 23 16 19 22 24 44 47 10 24 27 28 48 55 49 50 52 57 ...

Page 19: ... 08 Wear Personal Protection 64 SPW 11 Warning Parking on Slope 65 SPW 13 Warning Clean Debris 66 SPW 15 Warning Belt Shield Door 67 SPW 27 Equipment May Create Sparks 68 SPW 31 Explosion Hazard Ultra Low Sulfur Diesel 69 900 8901 14 Basic Safety Decal Kit Options may require additional decals 70 900 8900 56 Bandit Model 2590 Logo Decal Kit AdditionalDecalsforMachineEquippedWithATrackUndercarriage...

Page 20: ...lean surface so it is smooth and secure Peel off the remainder of the backer paper as you continue to stick the decal on the surface 6 Rub decal from the center outward to remove air bubbles and to secure contact 7 Combination English Spanish decals are typically standard Other foreign language decals are available and may be purchased Mail translated decals required to Bandit Industries Inc THE C...

Page 21: ...Bandit 19 Copyright 6 18 MODEL 2590 DECALS ...

Page 22: ...Bandit 20 Copyright 6 18 MODEL 2590 DECALS ...

Page 23: ... projectiles Prepare and set up the work site Make sure there are no loose tools cans lines or any other foreign objects in the area Anything not in use must be stored in a tool box or stowed away Stabilize the infeed hopper and tongue if unhooked from a tow vehicle Do not rely on a tongue jack to keep the machine stable if unhooked from a tow vehicle Make sure to chock the tires Check for and rem...

Page 24: ...sure it stays in your possession 9 Allow the machine to cool down 10 Remove all debris wood chips sawdust leaves etc from the machine 11 If transporting the machine follow the transport procedures MACHINE OPERATION NOTICE Chippers are not designed to cut chunk wood dimensional lumber including rail road ties or end cut logs standing on end Chipper knives coming in contact with a flat surface puts ...

Page 25: ...Bandit 21 Copyright 6 18 MODEL 2590 CONTROLS MACHINE ORIENTATION REFERENCE RADIATOR SIDE DRIVE SIDE INFEED HOPPER END DISCHARGE END ...

Page 26: ...Bandit 22 Copyright 6 18 MODEL 2590 CONTROLS CONTROL OPERATING PROCEDURES Trailer Radio Remote Control Tether Control REFER TO ELECTRONIC OPERATORS MANUAL Track Radio Remote Control ...

Page 27: ...ride switch wired into their systems In this case depress the pressure override button and turn the ignition switch all the way to the right now hold both until the engine starts Once there is oil pressure the override button may be released 1 Follow the daily start up and maintenance check list before starting the machine 2 Turn the ignition key to the on position 3 Ensure the machine e stops are...

Page 28: ...ry Disconnect Switch MACHINE E STOP if equipped MAIN CIRCUIT BREAKER Located on battery box CONTROLS CONTROL CABINET NOTICE Control panels may not be exactly as shown Air Brake Release GEM Gauge For Engine Ignition Switch 12V Power Outlet Fuses Data Link ...

Page 29: ...Bandit 25 Copyright 6 18 MODEL 2590 CONTROLS Top Feed Relief Valve 900 3942 62 VALVE LOCATIONS Bottom Feed Pressure Relief 900 3909 05 ...

Page 30: ...ET GEM Gauge For Engine Ignition Switch 12V Power Outlet Fuses Data Link Tether Receptacle BATTERY BOX MAIN CIRCUIT BREAKER Main Circuit Breaker Tripped Power 12V Fuse 30 amp Hood Light 12V Fuse 15 amp Battery Disconnect Switch Tether Receptacle Push to Reset ...

Page 31: ... Down Discharge Flipper Left Right Top Feedwheel Bottom Feedwheel Before attempting any type of maintenance disengage clutch wait for the disc drum to come to a complete stop turn off engine remove the ignition key make sure the ignition key is in your possession install the disc drum lock pin wait 2 minutes and then disconnect the battery DANGER Yoke Lock Switch ...

Page 32: ...Bandit 28 Copyright 6 18 MODEL 2590 CONTROLS Key Pad Controller Stabilizers and Discharge CONTROLS ...

Page 33: ...n install the disc drum lock pin wait 2 minutes and then disconnect the battery DANGER Knob Sliding Air Vent Vent Cover There are two air vents on each side of the drum housing of your machine The air vents can be opened or closed to adjust your chip throwing to your particular application The chip throwing distance has many variables for example type of material chipping size of material chipping...

Page 34: ...ike an overhead hoist loader lift truck etc that is rated for lifting that component Follow all OSHA instructions for lifting DANGER Use Chain Use Wooden Block Use Yoke Lock Pin Yoke Lock Before attempting any type of maintenance disengage clutch wait for the disc drum to come to a complete stop turn off engine remove the ignition key make sure the ignition key is in your possession install the di...

Page 35: ...tor key see Figure 2 The electric switch is bolted to a mount on top of the chipper hood and the actuator key is attached by a cable to the hood pin see Figure 1 If the chipper hood engine disable switch is not properly installed then the engine will not start or run If the chipper hood engine disable switch becomes disconnected while the chipper engine is running the engine will be shut down or b...

Page 36: ... Solenoid is Electronically activated to produce a magnetic pull which shifts the spool inside the hydraulic valve Shifting of the spool changes oil flow direction from operating forward or dumping oil to tank High or HI is the setting when the feedwheels will turn back on feeding operation Low or LO is the setting when the autofeed will reverse if equipped the feedwheels and then turn the feedwhe...

Page 37: ...dle towards you away from the machine The stabilizer control valve is the off position in the center position Rear Stabilizer Control Valve NOTE Remove the lock pin BEFORE operating this function The rear stabilizer control valve operates the rear stabilizer cylinder there will be one valve on each side of the machine near the rear stabilizer To lower the rear stabilizer push the control handle aw...

Page 38: ...e the air tank drain valve is closed Check brakes to make sure they are operating correctly 16 Remove all excess debris Remove any wood or debris which may have collected 17 Store all tools in the tool box and make sure all boxes and cabinets are closed and secured 18 Check tires for correct pressure cuts or damaged rims 19 Check lug nuts and retorque if necessary Check new units before operation ...

Page 39: ...ine remove ignition key make sure the ignition key is in your possession wait 2 minutes and then disconnect the battery and you must have the ignition key in your possession 9 Place the joystick swing out in the transport position if equipped 10 Make sure running lights turn signals and brake lights are visible when loader is in the transport position 11 Make sure all reflectors and or lights are ...

Page 40: ... the tongue or hitch according to the total machine package weight to correctly position the machine on the trailer bed 6 The loading ramps or loading gate of the trailer must be constructed to withstand the weight and forces involved in loading and unloading the machine 1 Make sure the trailer and towing vehicle are parked on a flat surface They must be stable on the surface with the brakes locke...

Page 41: ...Bandit 37 Copyright 6 18 MODEL 2590 MAINTENANCE MACHINE ORIENTATION REFERENCE RADIATOR SIDE DRIVE SIDE INFEED HOPPER END DISCHARGE END ...

Page 42: ...sc drum lock pin wait 2 minutes and then disconnect the battery MAINTENANCE Consult your engine manual for proper break in procedures Various engines require somewhat different procedures 1 Check the safety decals and engine gauges Replace any missing or damaged decals and or engine gauges 2 Check all safety equipment Check for proper operation Repair or replace as needed 3 Check entire machine fo...

Page 43: ...to engine manufacturer s manual recommendations 8 Check chipper drum to turn Very carefully manually with a pry bar or wood bar turn the chipper drum a full revolution This is to ensure the anvil and knives have proper clearance If the chipper drum is jammed with debris or frozen in place DO NOT attempt to start the engine and engage clutch until the chipper disc drum rotates freely 9 Check the co...

Page 44: ...Use compressed air and or pressurized water soap may also be needed to clean the radiator depending on the level and type of debris If pressurized water is used be careful not to turn the debris hard and pack solid between the radiator fins Make sure to clean the radiator in the correct direction depending on if the cooling fan is a sucker or a pusher do not propel the debris into the radiator wit...

Page 45: ...ipped Check for excessive damage or wear Replace if needed Keep pintle ring or 5th wheel greased to reduce wear 3 Check discharge and infeed hopper wear Check for wear on discharge infeed hopper and discharge direction adjustor build up repair or replace as needed 4 Inspect feedwheel motor connections sprockets and bushings Check and maintain correct torque on feedwheel motor connections sprockets...

Page 46: ...T THE CHIPPER BEARINGS WARNING WHEN YOU CHANGE CHIPPER KNIVES NOTICE USE CORRECT KNIFE AND HARDWARE DO NOT use a size or style chipper knife bolt or nut other than factory approved for this chipper see manual DO NOT over torque or under torque knife bolts and nuts see manual DO NOT resharpen knife more than minimum width see manual DO NOT use a knife bolt or nut which has been tightened over 5 tim...

Page 47: ...g MAINTENANCE BOLT TORQUE CHART THESE TORQUES ARE BASED ON DRY CLEAN THREADS DESCRIPTION BOLT SIZE TORQUE FT LBS TORQUE Nm Chipper Bearing Bolts 1 8 NC 500 678 Drum Bearing Housing Bolts 1 8 NC 325 441 Chipper Drum Bolt On Hub 7 8 9 NC 350 475 Drum Keyless Taperlock Bushing 170 230 Knife Bolts Babbitt Style 5 8 18 NF 210 285 Knife Holder Bolts 3 4 10 NC 250 339 Anvil 3 4 10 NC 250 339 Belly Band B...

Page 48: ...pen 19 Check all hoses fittings lines and tanks for damage and fluid leaks 20 Check hydraulic control valves and ensure they operate and shift correctly 21 Check fuel level Running out and repriming is time consuming 22 Check engine oil coolant levels and correct engine speed Follow ENGINE MANUFACTURER S manual specs 23 Check DEF level on Tier 4 engines Fill to engine manufacturer s manual recomme...

Page 49: ...eyor chain tightness and tracking 7 Check and retighten bearing bolts bearing lock collars and sheave bushings 8 Check connections and tightness of hydraulic pumps motors and gear boxes 9 Check hydraulic function pressures Set to specified PSI bar 10 Check and fill tires to rated pressure if equipped 11 Check and grease or oil wheel bearings follow axle MFG instructions if equipped Every month the...

Page 50: ...required to chip increases machine vibration and cause feeding problems The extra vibration will cause cracks to develop throughout the machine and void warranty 2 Belt Drives 1 Belts must be tightened several times in the first few days of operation 2 Proper belt tension 3 Proper belt alignment 1 Loose and slipping belts will affect the performance of feeding Burnt glazed and broke belts due to i...

Page 51: ... system is not working properly Look at any dump cartridges or solenoids on the hydraulic system often tapping of the block or removing the cartridge and cleaning it will take care of problems 1 Poor performance and will have down time for repairs 9 Feed System Slide Box 1 Open the bottom feedwheel clean out door and clean any debris to make sure no binding occurs 2 Adjust the yoke springs to the ...

Page 52: ...el Bearings X 1 shot of grease wipe off excess 3 Infeed Conveyor Bearings X 1 shot of grease wipe off excess 4 Hood Hinge X 1 to 2 shots of grease wipe off excess 5 Discharge Flipper X Daily wipe off excess 6 Steel Friction Areas pivoting hinged sliding rolling X Lubricate i e yoke lock pins cabinet doors radiator screen hinges etc 7 Pintle Eye Ring Towing Hitch X Grease to reduce wear 8 Infeed Ch...

Page 53: ...ly locations may vary depending on options or component manufacturer Lubrication point instructions are described on the machine in the Lubrication Coolant Section and Maintenance Section of this manual or component manufacturer s manual NOTICE LUBRICATION CHART 3 9 MAINTENANCE ...

Page 54: ...0 hours or once a month with an NLGI 2 lithium complex grease with an base oil viscosity of 220 cSt for example Mobil XHP 222 Multi Purpose Grease NLGI 2 B Chipper drum operating at too high RPM s DO NOT exceed recommended RPM s C Check the chipper bearing locking collars or locknut for tightness D Bearings worn out REPLACE 4 Chipper Bearings Running Too Hot A Lugging engine on large material keep...

Page 55: ... Only Bandit knives and hardware are recommended for use in your Bandit chippers Only then can you be assured of a quality product that fits and performs the best to the standards of excellence that is expected from the Bandit chipper NOTICE NOTICE CAUTION Chipper knives are sharp and can be dangerous It is always necessary for your protection to be extra careful and wear proper hand protection wh...

Page 56: ... 9 Sharpen rotate or replace the chipper knife Knives should be professionally ground maintaining angle and dimensional specifications Knives should be replaced in sets These sets are determined by the amount of resharpening done to the knives It should be reinstalled with another knife of comparable usage It helps to keep the disc drum balanced and it helps maintain chip quality Do not allow the ...

Page 57: ...and hardware KNIFE BABBITTING PROCEDURES 1 Insert the knives into the knife gauge and slide the spacers up tight to avoid overspill of the babbitt material 2 Heat the knife and knife gauge with a torch see Figure 1 This will prevent blow back which could occur if there were any moisture left in the fixture 3 Pour babbitt slowly from the ladle on to knife gauge between steps gradually filling the c...

Page 58: ...p on the knife 14 Thread the knife bolts through the top clamp and knife and hand tighten as far as possible Do Not Use an impact wrench to start the knife bolts the knife holder bolt holes can strip 15 Make sure the knife babbitt is tight against the back of the knife holder 16 Using the pattern shown in Figure 4 tighten and torque the knife bolts to 210 ft lbs 285 Nm After the bolts have been ti...

Page 59: ...holder is removed or replaced If replacing the counter knife apply Loctite 243 to the socket head cap screws and torque to 15 ft lbs 20 Nm Counter Knife Knife Holder Apply Loctite 243 to the knife holder bolts and torque to 250 ft lbs 339 Nm 1 3 2 5 4 6 7 9 8 Install the knives and torque the knife bolts to 210 ft lbs 285 Nm 1 2 3 5 4 6 MAINTENANCE ...

Page 60: ...lts Anvil Puller Block Anvil To Knife Gauge View looking through the feedwheels at the throat area Anvil Drum Head Knife Anvil To Knife Gauge MAINTENANCE View looking up underneath drum head and base area Anvil Bolts Torque To Specs Anvil Adjuster Eye Bolt Anvil Support Mount Anvil Adjuster Eye Bolt Anvil Push Pull Plate ...

Page 61: ...nife The anvil to knife clearance should be 120 inches 3 0 mm 5 Set the closest knife to this distance Do Not under any circumstance attempt to rotate the chipper drum while someone is inside the infeed hopper They may become seriously injured Do Not Do This ANVIL ADJUSTMENT PROCEDURE 1 To adjust the anvil first loosen two of the hex nuts on either the inside or outside of the anvil puller block I...

Page 62: ...st the belt tension loosen the four engine mounting bolts and the jam nuts on the engine adjuster on the radiator end of the engine 3 Adjust the belt tension with the engine adjuster on the clutch end of the engine If you have to push the engine with the adjuster the belts will tighten slightly after the engine is realigned 4 Use the engine adjuster on the radiator end of the engine to realign the...

Page 63: ... Bolt Check Sheave Alignment With a Straight Edge or String Engine Sheave Engine Sheave Chipper Sheave Adjuster Bolt Mounting Bolts YES NO BELT SHEAVE WORN BELT YES NO YES NO BELT SPACE GOOD BELT SHEAVE BELT SHEAVE WORN SHEAVE Worn or misaligned belts and sheaves in the power train causes belt slippage thus power loss Keep the power train working for you not against you by checking for needed adju...

Page 64: ...in The infeed chain should have a clearance of 1 4 to 3 8 6 10 mm from the conveyor bed in the middle between the conveyor wheels See Figure 1 7 Running the infeed conveyor chain too loose may cause premature wear and running the infeed conveyor chain too tight may cause premature failure 8 When adjustment is finished be sure to tighten the bearing or bearing adjuster bolts and nuts INFEED MAINTEN...

Page 65: ...t Jam Nut Bearing Adjuster Mounting Bolts There is one conveyor bearing adjuster on each side of the conveyor of your machine The bearing adjuster must be adjusted equally on both sides Count the number of threads on each side as you adjust the infeed conveyor Remember to tighten the bearing adjuster when finished NOTICE ...

Page 66: ...spection plate 6 Please refer to the Twin Disc service maintenance manual if there are required adjustments needed to meet the torque values listed on the inspection cover 7 Reinstall the clutch handle and hardware that was removed once clutch engagement torque check is completed DANGER TWIN DISC SP318 CLUTCH HANDLE TORQUE Remove hardware and install socket here to check torque Before attempting a...

Page 67: ...the discharge DANGER DANGER Figure 1 Figure 2 Figure 3 Figure 4 Remove Cylinder Pin Discharge Lifting Lug Unhook side and top cylinder hoses Lift Discharge Up Before attempting any type of maintenance disengage clutch wait for the disc drum to come to a complete stop turn off engine remove the ignition key make sure the ignition key is in your possession install the disc drum lock pin wait 2 minut...

Page 68: ...between the conveyor wheels Bolt the clean out doors back in place after the material is removed DANGER Before attempting any type of maintenance disengage clutch wait for the disc drum to come to a complete stop turn off engine remove the ignition key make sure the ignition key is in your possession install the disc drum lock pin wait 2 minutes and then disconnect the battery CONVEYOR CLEAN OUT D...

Page 69: ... frame 6 Remove both feedwheel bearings from the bottom feedwheel shaft 7 Swing the right side end of the bottom feedwheel forward towards the engine until it clears the frame 8 Drop the right side end of bottom feedwheel down and out between the axles BOTTOM FEEDWHEEL REMOVAL Figure 1 Remove the drive chains sprockets and bushings DANGER Before attempting any type of maintenance disengage clutch ...

Page 70: ...proximately 1 2 full and apply some grease to the bearing cap See Figures 3 through 5 10 Reinstall the bearing cap and tap with a rubber hammer until the top and bottom halves of the bearing housing are seated 11 Ensure mating surfaces are clean and labyrinth seals are seated properly Match marks have to line up 12 Clean the bearing housing cap bolts and lightly oil 13 Reinstall the four bearing h...

Page 71: ...op towel and place on a clean surface Inspect grease condition for extreme wear contamination or water emulsification High amount of contamination present With nitrile gloves on and with a clean rag manually scoop and wipe out grease from cavity and place in disposal bucket Changing from one grease to another Manually work new grease into the bearing and fill the housing to approximately 1 2 full ...

Page 72: ... external splines of the hydraulic pump The tops of the splines should be flat If the splines are pointed they are wore and need to be replaced If the splines are good pack the internal splines of the bearing block with an EP 2 Lithium type grease reinstall the hydraulic pump and bolt the hydraulic pump to the bearing block The fluid in the bearing block needs to be checked weekly and kept full wi...

Page 73: ...e tool manufacturer s safety and installation instructions CHAIN PULLER DANGER Before attempting any type of maintenance disengage clutch wait for the disc drum to come to a complete stop turn off engine remove the ignition key make sure the ignition key is in your possession install the disc drum lock pin wait 2 minutes and then disconnect the battery MAINTENANCE ...

Page 74: ...n to turn the chipper drum when someone else is working inside the chipper housing More than likely the chipper drum will turn hard then loosen causing it to turn faster If another person is anywhere near the chipper drum they may be injured 7 Never turn the chipper drum by hand Always use a pry bar or wood bar This will prevent the person turning the drum from being injured should the drum break ...

Page 75: ...ent Follow axle MFG instructions Brakes uneven or misadjusted brakes cause irregular brake activation MAINTENANCE TIRE WEAR DIAGNOSTIC CHART For additional parts break downs and service videos go to www dexteraxle com Wear Pattern Cause Action Edge Wear Under inflation Adjust pressure to particular load per tire catalog Side Wear Not hauling trailer level Bent axles Wide tires Wheel bearings Must ...

Page 76: ...rted that some equipment owners polish their machine at least yearly and keep good mud flaps on their towing trucks to prolong the machines paint WINDOW WASHING INSTRUCTIONS DO NOT use any glass cleaner on windows Follow these steps to clean the windows DO NOT USE RAZOR BLADES SCRAPERS SQUEEGEES ETC 1 Rinse with water to remove abrasive dirt 2 Wash with soap or mild detergent using a soft cloth sp...

Page 77: ...o check for leaks Lower load or relieve hydraulic pressure before loosening fittings Relieve all pressure in the system before disconnecting the lines hoses or performing other work Use a piece of cardboard to find leaks Never use your bare hands Allow system to cool down to ambient temperature before opening any coolant or hydraulic oil system In cold weather situations let your hydraulic system ...

Page 78: ...nder increasing temperature and their ability to separate water from the fluid Viscosity is temperature dependent Fluids with high viscosity index VI will thin out slower at higher temperature and thicken slower at colder temperatures allowing a wider operating range Choose a fluid that has test results in these areas for best results Based on the varying temperatures of the area where Bandit equi...

Page 79: ...T PARTS AS WELL AS HYDRAULIC PARTS These typical hydraulic flows and relief pressure settings are with the engine at full RPM All settings are subject to change NOTICE NOTICE CAUTION HYDRAULICS Equipment Model 2590 Top Feedwheel GPM LPM 32 121 Bottom Feedwheel GPM LPM 23 87 Accessory GPM LPM 15 57 Top Feedwheel Relief PSI bar 2300 158 Bottom Feedwheel Relief PSI bar 2300 158 Conveyor Relief PSI ba...

Page 80: ...Refer to their manuals and maintenance section of this manual HYDRAULICS After the initial start up of the machine and after any replacement of hydraulic components that fittings and hoses should be re checked for leaks and clearances CAUTION THE BANDIT HYDRAULIC SYSTEM HYDRAULICS After you have operated a new machine for approximately an hour shut down the machine and recheck all hydraulic fittin...

Page 81: ...es operate properly They must function shift and position smoothly and accurately at all times Faulty controls can cause personal injury It is very important after you have operated a new machine for approximately an hour to shut down the machine and recheck all hydraulic fittings Retighten as needed DONOTGONEARHYDRAULICLEAKS Highpressureoileasilypuncturesskincausingseriousinjury gangrene or death...

Page 82: ...Clean reset or replace Pump is worn Replace Motor is worn Replace Feedwheel slide box sticking or hanging up Lubricate Feedwheel s turn slowly or not at all Relief valve stuck open Clean or replace Worn hydraulic motor Replace Pump is worn Replace Feedwheel relief pressure not correct Reset to specified PSI bar Pinched or damaged hydraulic hose Replace Feedwheel valve control valve worn leaking in...

Page 83: ...he relief valve setting Contact your nearest dealer or Bandit Industries for instructions to adjust the relief valve setting Contact your nearest dealer or Bandit Industries for instructions to clean the relief valve 1 See pages 82 83 on how to check a hydraulic pump 1 If everything checks out as correct it may be time to check the hydraulic motor 2 If your machine has Live Hydraulics see page 81 ...

Page 84: ...___________________________________________________ vantages and options DPC130 Tie rods tightening 22 lbft B Port Valve A Load Sense Relief A Port Valve B Load Sense Relief NOTE Refer to check sheet or machine S N when ordering parts HYDRAULICS ...

Page 85: ... some machines will be equipped with a flow divider between the hydraulic motor and the control valve If the hydraulic motor has a case drain unhook the case drain hose that goes to the relief valve at the valve and put the hose into the hydraulic tank 4 Place the end of the hose in a clean 5 gallon 19L pail 5 Plug the open port of the control valve or main relief valve 6 Unhook the other hose in ...

Page 86: ...O ALLOW UNRESTRICTED FLOW TO PASS THROUGH IT 8 Start the engine to engage the pump the clutch may have to be engaged if the pump is belt driven 9 Have a second person lift the hydraulic hose far enough out of the tank inlet to observe the flow of oil going into the tank Observe the pressure gauge reading to make sure a high pressure does not exist 10 Increase the engine speed slowly to full rpm an...

Page 87: ...ate through the meter and pressure gauge reading to make sure a high pressure does not exist 8 Increase the engine speed slowly to full rpm and at the same time observe the pressure and flow rate The pressure should still remain low Make a note of the flow rate gpm or Lpm at full engine rpm 9 SLOWLY turn the needle valve on the flow control in and observe the pressure increase on the pressure gaug...

Page 88: ...ghts Brown BR N A TYPICAL ELECTRICAL WIRING DIAGRAMS 6 BROWN N A 1 WHITE GROUND 2 BLACK RUNNING LIGHT 3 YELLOW LEFT TURN 4 RED BRAKE LIGHT 5 GREEN RIGHT TURN 6 WIRE MAIN CABLE W BL W BL AMBER MARKER LIGHT AMBER MARKER LIGHT RED MARKER LIGHT RED MARKER LIGHT LEFT TURN LIGHT RIGHT TURN LIGHT BRAKE LIGHT BRAKE LIGHT 3 LIGHT MARKER BAR BL BL BL BL BL BL BL R G W W W Y R ...

Page 89: ...ent parts you should have the serial number S N and model of the machine to ensure that you receive the correct replacement part See page 6 for typical serial number work order number locations NOTICE Bandit Industries Inc reserves the right to make changes in models size design installations and applications on any part without notification NOTICE Some of the components shown in this section are ...

Page 90: ...2590 INFEED HOPPER COMPONENTS Parts may not be exactly as shown NOTICE 2 11 3 1 7 8 9 10 4 6 4 4 5 7 4 12 13 4 4 8 9 8 9 14 15 16 8 17 18 19 20 15 23 21 26 27 4 4 28 8 29 30 31 32 34 33 35 29 37 38 30 36 39 15 14 22 25 24 YOKE INFEED ...

Page 91: ...ly 12 955 300086 Trap Door Assembly Pin 13 259 2000 94 Bottom Feedwheel Assembly 14 959 3001 53 Lexan Work Light Cover 15 900 2926 79 Work Light 16 900 1915 55 Driven Bushing 17 259 2002 72 Conveyor Gear Box Mount 18 900 3942 59 Conveyor Gear Box 19 900 6907 69 Gasket 20 900 3943 57 Hydraulic Motor 21 920 300330 Yoke Support Top 22 900 3925 07 Yoke Cylinder 23 259 2000 84 Yoke Top Assembly 24 a 90...

Page 92: ...Bandit 88 Copyright 6 18 MODEL 2590 CHIPPER COMPONENTS Parts may not be exactly as shown NOTICE CHIPPER BASE 1 2 3 5 15 8 8 7 11 10 9 12 12 11 10 9 13 14 18 19 17 22 23 24 20 21 25 16 4 6 ...

Page 93: ...259 1001 69 Chipper Drum Assembly 500 Hp 7 977 100101 Drum Bearing Radiator Side 8 259 2002 56 Base Divider Plate Assembly Chip Breaker 9 900 4908 29 Plastic Knob For Air Vents 10 937 300007 Air Vent Cover 11 259 3003 48 Vent Cover 12 259 3002 37 Base Chipper Shaft Slot Cover 13 259 2002 55 Replaceable Upper Belly Band Back Half Dividers 14 a 259 2004 44 Replaceable Lower Belly Band Assembly b 259...

Page 94: ...um Assembly 3 938 200133 Drum End Plate Assembly 4 900 1914 34 Keyless Locking Bushing 5 259 3005 52 Keyless Locking Bushing Cover Plate 6 977 301610 Keyless Locking Bushing Cover Plate 7 a 259 3013 82 5 Drum Head Shaft 440 HP 499 HP b 259 3014 86 5 Drum Head Shaft 500 HP c 259 3000 68 4 15 16 Drum Head Shaft 440 HP 499 HP d 259 3005 21 4 15 16 Drum Head Shaft 500 HP 8 See Pages 92 93 Drum Knife P...

Page 95: ...0 Drum Assembly 3 938 200133 Drum End Plate Assembly 4 900 1914 34 Keyless Locking Bushing 5 259 3005 52 Keyless Locking Bushing Cover Plate 6 977 301610 Drum Bushing Cover Plate 7 a 259 3013 82 5 Drum Head Shaft 440 HP 499 HP b 259 3014 86 5 Drum Head Shaft 500 HP c 259 3000 68 4 15 16 Drum Head Shaft 440 HP 499 HP d 259 3005 21 4 15 16 Drum Head Shaft 500 HP 8 See Pages 92 93 Drum Knife Pocket A...

Page 96: ...TYLE KNIFE LOCATION PART NUMBER DESCRIPTION 1 500 0001 16 Knife Saver Kit 2 900 9901 65 File For Knife Saver Kit Only 3 900 9914 29 Replacement Blades For Knife Saver 4 900 9914 24 Knife Changing Gloves KNIFE SAVER KIT 6 7 10 5 4 3 2 8 9 1 259 1000 93 Micro Chip Pocket Assembly 2 259 3013 33 Knife Holder Babbitt Style Knife 3 259 3004 84 Counter Knife 4 900 4909 76 1 4 20 x 1 2 SHCS Counter Knife ...

Page 97: ...1 16 Knife Saver Kit 2 900 9901 65 File For Knife Saver Kit Only 3 900 9914 29 Replacement Blades For Knife Saver 4 900 9914 24 Knife Changing Gloves KNIFE SAVER KIT 3 2 4 5 1 CHIPPER KNIFE HARDWARE BOLT IN STYLE KNIFE Knife Holders Knife Holder Bolts Knife Gauges for other chip sizes available upon request 1 938 300005 Knife Holder 2 900 4914 30 3 4 10NC x 2 1 4 SHCS Knife Holder Bolt 3 900 9902 ...

Page 98: ...CE FEED DIRECTION 1 259 3001 20 Anvil Only 2 900 4903 21 3 4 Mill Carb Washer 3 900 4902 75 Adjuster Eye Bolt 5 8 x 6 4 900 4907 04 5 8 11NC Nut 5 900 4901 32 5 8 Mill Carb Washer 6 900 4907 17 3 4 Lock Washer 7 900 4912 80 3 4 10NC x 4 Bolt 8 900 4907 14 3 4 10NC x 3 Bolt 9 955 300193 Anvil to Knife Gauge 10 900 4921 24 Anvil Hardware Kit Includes Items 2 8 ...

Page 99: ...ring Insert 4 15 16 or 5 4 a 900 1911 87 Grease Seal Includes Seal Ring 1 per on Radiator Side Bearing 4 15 16 b 900 1921 83 Grease Seal Includes Seal Ring 1 per on Radiator Side Bearing 5 5 900 1911 89 Bearing End Cap Not Shown 4 15 16 or 5 6 a 900 4909 15 1 8NC x 6 Bearing Housing Cap Bolt Not Shown b 900 4914 25 1 8NC x 12 1 2 Bearing Housing Cap Bolt Not Shown c 900 4913 52 1 8NC Automation Lo...

Page 100: ...9 25 Discharge Top Plate Lower Section 3 259 3009 26 Discharge Top Plate Middle Section 4 259 3009 27 Discharge Top Plate Top Section 5 900 3943 75 Discharge Tilt and Swivel Cylinder 6 938 1000 25 Discharge Flipper Chute Swivel Shaft 7 259 2000 36 Discharge Flipper Chute Outer Assembly 8 259 2000 56 Discharge Flipper Chute Inner Assembly 9 930 3010 23 Discharge Clean Out Door Top Section 10 259 30...

Page 101: ... Stauff Clamp 3 259 3006 34 Discharge Chute Top Removable Plate 4 900 3943 75 Discharge Tilt and Swivel Cylinder 5 938 1000 25 Discharge Flipper Chute Swivel Shaft 6 259 2000 36 Discharge Flipper Chute Outer Assembly 7 259 2000 56 Discharge Flipper Chute Inner Assembly 8 900 3925 03 Discharge Lift Cylinder 9 259 3003 56 Discharge Clean Out Door Upper 10 259 3003 57 Discharge Clean Out Door Lower ...

Page 102: ...Bandit 98 Copyright 6 18 MODEL 2590 LOADER COMPONENTS Parts may not be exactly as shown NOTICE Parts may not be exactly as shown NOTICE ...

Page 103: ...edestal Assembly 12 900 1901 42 Spherical Bearing 13 900 4905 44 Nut 14 a 975 0500 28 Jib Boom Cylinder b 900 3905 55 Rotobec Jib Boom Cylinder 15 975 200022 Jib Boom 16 960 200078 Jib Boom To Grapple Swing Damper Pin 17 975 200054 Jib Boom Cylinder To Jib Boom Pin 18 975 200076 Jib Boom To Main Boom Pin 19 900 1915 89 Bushing 20 900 1901 42 Split Bushing 21 975 200054 Jib Boom Cylinder To Main Bo...

Page 104: ...ORY COMPONENTS Parts may not be exactly as shown NOTICE Parts may not be exactly as shown NOTICE 22 28 14 Pintle Hitch Option 15 13 14 13 26 16 19 17 20 18 15 21 15 23 24 25 15 29 30 27 32 12 12 6 2 1 8 11 10 9 6 5 2 1 4 3 4 3 3 3 7 31 5 33 2590 FRAME ...

Page 105: ...900 4908 19 T Handle Latch c 900 9902 24 Key Not Shown 23 259 2002 64 Front Stabilizer Assembly Right Side See page 102 24 930 2000 83 Tilt Up Step Assembly 25 955 1014 77 Valve Bank Cover 26 259 3020 43 Mud Flap Mount Strap 27 900 9909 31 Mud Flap 28 259 1001 83 Suspension Assembly 29 a 900 5909 43 Axle Assembly 8 Bolt hub b 900 5913 95 Axle Assembly 10 Bolt hub 30 a 900 5909 17 10R17 5 Tire Rim ...

Page 106: ...n NOTICE LOCATION PART NUMBER DESCRIPTION 1 259 2004 51 Stabilizer Top Housing Left Side 2 900 3953 08 Stabilizer Cylinder 3 900 4905 19 Hair Pin Clip 4 955 300086 Stabilizer Leg Pin 5 259 2004 52 Stabilizer Top Housing Right Side 6 259 2004 50 Stabilizer Inner Leg 7 259 2004 49 Stabilizer Bottom Leg 8 900 3917 25 Small Stauff Clamp ...

Page 107: ...9 2000 34 Fuel Tank Complete 130 gal 492 Liter 2 900 3900 73 Bushing 3 900 3933 66 Fuel Suction Pipe 4 977 304518 Fuel Cap Locking Cover 5 900 2923 93 29 Fuel Sender 6 980 0125 85 Fuel Tank Lock Bar 7 900 3917 71 Filler Cap Black Plastic 8 900 2904 14 29 1 2 Sight Gauge Non Electric 9 900 3922 60 3 4 Magnetic Drain Plug 10 a 900 3952 62 Fuel Cap Vented b 900 3947 93 Filler Neck Strainer c 900 3947...

Page 108: ...3 05 Fuel Tank Complete 200 gal 757 Liter 2 900 3900 73 Bushing 3 900 3933 66 Fuel Suction Pipe 4 977 304518 Fuel Cap Locking Cover 5 900 2923 93 29 Fuel Sender 6 980 0125 85 Fuel Tank Lock Bar 7 900 3917 71 Filler Cap Black Plastic 8 900 2902 24 32 Sight Gauge Non Electric 9 900 7900 14 Rubber Isolator 10 960 300489 Fuel Tank Mount 11 900 3922 60 3 4 Magnetic Drain Plug 12 a 900 3952 62 Fuel Cap ...

Page 109: ...4518 Fuel Cap Locking Cover 4 249 3007 66 Temporary Filter Cover 5 259 2003 96 Engine Fluid Heater Loop 6 977 303477 Engine Fluid Heater Loop Mount Gasket 7 980 0125 85 Fuel Tank Lock Bar 8 900 3917 71 Filler Cap Black Plastic 9 900 2903 93 12 Sight Gauge Non Electric 10 900 3932 05 O Ring Tank Strainer 1 11 900 3925 21 O Ring Tank Strainer 1 1 2 12 900 3922 60 3 4 Magnetic Drain Plug 13 960 30048...

Page 110: ...Bandit 106 Copyright 6 18 MODEL 2590 ENGINE COMPONENTS Parts may not be exactly as shown NOTICE 32 5 7 6 6 4 3 2 1 3 8 9 11 10 10 12 13 14 22 26 27 28 29 30 31 23 24 25 21 20 19 18 17 18 16 15 4 14 ...

Page 111: ... Circuit Breaker 9 900 2908 04 Start Up Beeper 10 900 6907 88 Battery 8D MHD 11 930 2001 24 Battery Box Assembly 12 259 3011 77 Engine Clutch Plate PT Tech Clutch 13 Clutch 14 900 2910 17 Amber Marker Light Round 15 259 2004 46 Air Cleaner Support PT Tech Clutch 16 930 2003 35 Engine Canopy Assembly 17 959 2003 39 Engine Exhaust Flange 45 18 900 6910 49 Exhaust Clamp 19 Exhaust Flex Tubing 20 900 ...

Page 112: ...nge without notice refer to the machine check sheet for the hydraulic part numbers NOTICE LOCATION PART NUMBER DESCRIPTION Flex Fan Valve 900 6913 80 1 2 3 1 900 3932 95 Internal Hydraulic Return Filter Ass y Includes 2 2 900 3931 34 Filter Only For Internal Hydraulic Return Filter Ass y 3 900 3944 48 Filter Gauge ...

Page 113: ...0 HYDRAULIC COMPONENTS T Manifold 900 3917 50 Counter Balance 900 3923 05 Pilot Block 900 3983 12 Bottom Feed Pressure Relief 900 3909 05 Dual Pilot Valve 900 3949 09 Splitter Manifold 960 0020 89 Parts may not be exactly as shown NOTICE ...

Page 114: ...lenoid Only 12 Volt 2 900 3908 23 Relief Only 3 900 3907 69 Valve Section With 24 Volt Solenoids Flipper Up Down Flipper Left Right Discharge Up Down 4 900 3907 99 Valve Section With 12 Volt Solenoids Flipper Up Down Flipper Left Right Discharge Up Down 5 900 3901 69 Valve Section With 24 Volt Solenoids Yoke Up Down 6 900 3907 12 Valve Section With 12 Volt Solenoids Yoke Up Down Valve Bank 900 397...

Page 115: ... 31 Pin And Cotter Key For Control Valve 5 904 0003 32 Bracket Handle And Chain Link 6 NOTE INCLUDES s 1 2 3 4 7 900 3937 34 Seal Kit For Control Valve 8 904 0003 33 Seal Retainer For Control Valve NOTE NOT INCLUDED IN SEAL KIT 9 900 3901 12 Relief Valve Kit Spring Ball Screw NOTE SOLD ONLY AS A KIT 10 904 0003 34 Valve Spool Stop For Spring Loaded Valve 11 904 0003 35 Valve Spool Spring 12 904 00...

Page 116: ...ly Includes s 1 4 d 900 3914 02 1 2 Single Clamp Assembly For Steel Lines Includes s 1 4 e 900 3915 61 1 2 Double Clamp Assembly Includes s 1 4 f 900 3913 32 1 2 Double Clamp Assembly For Steel Lines Includes s 1 4 g 900 3914 03 3 4 Single Clamp Assembly Includes s 1 4 h 900 3914 07 3 4 Double Clamp Assembly Includes s 1 4 i 900 3914 04 1 Single Clamp Assembly Includes s 1 4 j 900 3914 05 1 1 4 Si...

Page 117: ...kers b 900 3919 96 Main Relief Only Danfoss 3 900 3923 48 Main Relief Block Assembly Includes s 1 2 1 900 3920 20 Retainer Nut Danfoss 2 900 2909 55 Herschman Connector Only 3 a 900 3923 58 24 Volt Solenoid Only Danfoss b 900 3920 19 12 Volt Solenoid Only Danfoss 4 a 900 3940 61 24 Volt Solenoid Assembly Danfoss Includes s 1 3a 4 6 b 900 3919 47 12 Volt Solenoid Assembly Danfoss Includes s 1 3b 4 ...

Page 118: ...DRAULIC COMPONENTS Flow Control Valve Top Feedwheel 900 3942 61 Flow Control Valve Bottom Feedwheel 900 3924 54 Top Feed Relief Valve 900 3942 62 Auxiliary Pump 900 3942 65 Hydraulic Pump 900 3943 56 Parts may not be exactly as shown NOTICE ...

Page 119: ...R DESCRIPTION Parts may not be exactly as shown NOTICE 1 900 5903 81 Glad Hands 2 900 3911 17 Coil Flex Hoses 1 Set 3 034 057 01 Air Chamber 4 900 3925 61 Quick Release Valve 5 a 900 5905 56 Air Tank b 900 9900 34 150 PSI Pop Off Valve Not Shown 6 900 5905 57 Air Tank Regulator ...

Page 120: ...Bandit 116 Copyright 6 18 MODEL 2590 SERVICE RECORD SERVICE RECORD DATE DESCRIPTION AMOUNT ...

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