Bobcat Toolcat 5600 Utility Work Machine Workshop Repair Service Manual - 6901892

(S/N: 520511001 & Above) 
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This workshop repair service manual PDF download for the Toolcat™ 5600 Bobcat Utility Work Machine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Utility Work Machine Toolcat™ 5600 
S/N: 520511001 & Above


TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS 
FIRE PREVENTION 
SERIAL NUMBER LOCATIONS 
DELIVERY REPORT
BOBCAT UTILITY WORK MACHINE IDENTIFICAITON 
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM 
HYDROSTATIC SYSTEM 
DRIVE SYSTEM 
MAIN FRAME 
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING 
SPECIFICATIONS
SERVICE MANUAL REVISION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6901892 (5-09)
Total Pages : 602


This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
    FOREWORD
    SAFETY INSTRUCTIONS
    FIRE PREVENTION
        Maintenance
        Operation
        Electrical
        Hydraulic System
        Fueling
        Starting
        Spark Arrestor Exhaust System
        Welding And Grinding
        Fire Extinguishers
    SERIAL NUMBER LOCATIONS
        Work Machine Serial Number
        Engine Serial Number
    DELIVERY REPORT
    BOBCAT UTILITY WORK MACHINE IDENTIFICAITON
    
SAFETY AND MAINTENANCE
    LIFTING AND BLOCKING THE MACHINE
        Procedure For Jackstand Placement On The Axle
        Procedure For Jackstand Placement On The Frame
    LIFT ARM SUPPORT DEVICE
        Installing The Lift Arm Support Device
        Removing the Lift Arm Support Device
    CARGO BOX SUPPORT DEVICE
        Installing The Cargo Box Support Device
        Removing the Cargo Box Support Device
    OPERATOR CAB
        Description
    TRANSPORTING THE TOOLCAT
        Loading Onto Transport Vehicle
        Fastening To Transport Vehicle
    TOWING THE MACHINE
        Procedure
    REMOTE START
        Procedure
    SERVICE SCHEDULE
        Chart
    AIR CLEANER SERVICE
        Replacing Filter Elements
    ENGINE COOLING SYSTEM
        Checking The Coolant Level
        Cleaning The Cooling System
        Removing & Replacing Coolant
    FUEL SYSTEM
        Fuel Specifications
        Filling The Fuel Tank
        Fuel Filter
        Removing Air From The Fuel System
    ENGINE LUBRICATION SYSTEM
        Checking Engine Oil
        Oil Chart
        Replacing The Oil And Filter
    HYDRAULIC / HYDROSTATIC SYSTEM
        Checking And Adding Fluid
        Replacing Hydraulic/Hydrostatic Filter
        Replacing Hydraulic Fluid
        Hydraulic Fluid Chart
        Reservoir Breather
    AXLE/DIFFERENTIAL (FRONT & REAR)
        Checking And Adding Lubricant
        Replacing Lubricant
    BOB-TACH
        Inspection And Maintenance
    LUBRICATION
        Lubrication Locations
    TIRE MAINTENANCE
        Wheel Nuts
        Tire Rotation
        Mounting
    SPARK ARRESTOR MUFFLER
        Maintenance
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    HYDRAULIC SYSTEM INFORMATION
        Glossary
        Tighten Procedures
        Troubleshooting Chart
    CYLINDER (LIFT)
        Checking
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (TILT)
        Checking
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (CARGO BOX)
        Checking (Left Side Cylinder)
        Checking (Right Side Cylinder)
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    MAIN RELIEF VALVE
        Checking
        Adjustment
        Removal And Installation
    PORT RELIEFS
        Checking The Port Relief Valve (Lift)
        Checking The Port Relief Valves (Tilt)
    WORK VALVE
        Removal And Installation
        Disassembly and Assembly
    STEERING AND CARGO BOX VALVE
        Removal And Installation
        Disassembly and Assembly
    AUXILIARY HYDRAULIC VALVE
        Removal And Installation
        Disassembly And Assembly
    POWER STEERING PUMP
        Removal And Installation
        Disassembly And Assembly
    PILOT VALVE
        Removal And Installation
        Disassembly And Assembly
    LIFT ARM BY-PASS CONTROL VALVE
        Inspecting
        Removal And Installation
        Disassembly And Assembly
    HYDRAULIC PUMP
        Checking The Auxiliary Section Of The Hydraulic Pump
        Checking The Work Group Section Of The Hydraulic Pump
        Checking The Steering And Cargo Box Section Of The Hydraulic Pump
        Removal And Installation
        Disassembly And Assembly
    HYDRAULIC/HYDROSTATIC FILTER
        Housing Removal And Installation
    CONTROL LEVER (JOYSTICK)
        Joystick Handle Removal And Installation
        Joystick Removal And Installation
        Joystick Disassembly and Assembly
    HYDRAULIC FLUID RESERVOIR
        Removal And Installation
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
        Removal And Installation
        Disassembly And Assembly
    REMOTE HYDRAULICS DIVERTER VALVE
        Removal And Installation
        Disassembly And Assembly
        
HYDROSTATIC SYSTEM
    HYDROSTATIC SYSTEM INFORMATION
        Troubleshooting Chart
        Replenishing Valve Function
    HYDROSTATIC MOTOR
        Removal and Installation (Front Axle)
        Removal and Installation (Rear Axle)
        Disassembly
        Assembly
    CHARGE PRESSURE
        Checking Charge Pressure
    HYDROSTATIC PUMP
        Removal and Installation
        Directional Control Valve Removal and Installation
        PWM Control Valve Removal and Installation
        Replenishing/High Pressure Relief Valve
        Charge Relief Valve
        Disassembly
        Inspection
        Assembly
        Hydrostatic Pump Start-Up
        Neutral Adjustment
    DRIVE BELT
        Shield Removal And Installation
        Adjusting
        Drive Belt Replacement
        Tensioner Pulley Removal And Installation
        Tensioner Pulley Parts Identification
        Tensioner Pulley Disassembly
        Tensioner Pulley Assembly
    OIL COOLER
        Removal and Installation
        
DRIVE SYSTEM
    BRAKE
        Disassembly & Assembly (Front Axle)
        Disassembly & Assembly (Rear Axle)
    AXLE
        Front Axle Brush Guard Removal And Installation (S/N 520511246 & Below)
        Front Axle Brush Guard Removal And Installation (S/N 520511247 & Above)
        Front Axle Removal And Installation
        Rear Axle Removal And Installation
        Disconnecting The Axle Housings
        Primary Housing Disassembly
        Steering Cylinder Disassembly
        Brake Disassembly
        Secondary Housing And Differential Lock Disassembly
        Secondary Housing And Differential Lock Assembly
        Steering Cylinder Assembly
        Primary Housing Assembly
        Brake Assembly
        Connecting The Axle Housings
    AXLE HUB WITH AXLE SHAFT
        Removal And Installation (Without Wheel Position Sensor)
        Removal (With Wheel Position Sensor)
        Inspection
        Installation (With Wheel Position Sensor)
    AXLE HUB WITHOUT AXLE SHAFT
        Removal And Installation (Without Wheel Position Sensor)
        Removal (With Wheel Position Sensor)
        Bearing Pivot Inspection
        Installation (With Wheel Position Sensor)
        Disassembly
        Axle Hub Inspection
        Assembly
        Torque Check Procedure
    TIE ROD
        Removal And Installation (Front Axle)
        Removal And Installation (Rear Axle)
        Adjusting
    AXLE SHAFT
        Removal and Installation
        
MAIN FRAME
    OPERATOR CAB
        Removal And Installation
    OPERATOR SEAT
        Removal And Installation
        Seat Belt Removal And Installation
        Seat Pan Removal And Installation
        Slide Rail Removal And Installation
        Cushion Removal And Installation
        Back Removal And Installation
        Arm Rest Bracket Removal And Installation
        Arm Rest Removal And Installation
        Shock Removal And Installation
    PASSENGER SEAT
        Removal And Installation
        Seat Belt Removal And Installation
        Seat Pan Removal And Installation
        Arm Rest Removal And Installation
    BOB-TACH
        Removal and Installation
        Bob-Tach Lever and Wedge
    LIFT ARM
        Removal and Installation
    CARGO BOX
        Removal and Installation
    STEERING COLUMN
        Removal And Installation
    FUEL TANK
        Removal and Installation
    TRAVEL AND BRAKE PEDALS
        Removal And Installation
        Travel Speed Pedal Disassembly and Assembly
    SHOCKS
        Removal And Installation
    TRAILING ARMS
        Removal And Installation (Upper Arm)
        Removal And Installation (Lower Arm)
    LEAF SPRINGS
        Removal And Installation (Left Side)
        Removal and Installation (Right Side)
    HITCH
        Removal And Installation
    FLOOR CONSOLE
        Removal And Installation
    CENTER CONSOLE
        Removal And Installation
    FENDER (FRONT LEFT)
        Removal And Installation
    FENDER (FRONT RIGHT)
        Removal And Installation
    FENDER (REAR LEFT)
        Removal And Installation
    FENDER (REAR RIGHT)
        Removal And Installation
        
ELECTRICAL SYSTEM & ANALYSIS
    ELECTRICAL SCHEMATICS
    ELECTRICAL SYSTEM INFORMATION
        Troubleshooting Chart
        Description
        Fuse Location
        Solenoid Test
    BATTERY
        Removal And Installation
        Servicing
        Using A Booster Battery (Jump Starting)
    ALTERNATOR (90 AMP)
        Adjusting The Alternator Belt
        Alternator Identification
        Charging System Check
        Alternator Voltage Test
        Low Voltage Test
        High Voltage Test
        Removal And Installation
        Rectifier Continuity (Diode) Test
        Alternator Regulator Test
        Disassembly
        Stator Continuity Test
        Stator Ground Test
        Rotor Continuity Test
        Rotor Ground Test
        Assembly
    STARTER
        Checking
        Removal And Installation
        Parts Identification
        Disassembly and Assembly
        Inspection And Repair
        No Load Test
    INSTRUMENT PANEL
        Display Controller Panel
        Switch Panel
        Center Console
        Display Controller Panel Removal And Installation
        Center Console Removal And Installation
        Light Bulb Removal And Installation
    LIGHTS
        Front Removal And Installation
    DISPLAY CONTROLLER
        Identification Chart
        Removal And Installation
    DRIVE CONTROLLER
        Identification Chart
        Removal And Installation
    DIAGNOSTICS
        Service Codes
    TICS SYSTEM
        Inspecting the TICS System (Engine STOPPED - Key ON)
        Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)
        Inspecting The Arm Rest Sensor (Engine RUNNING)
        Inspecting The Traction Lock (Engine RUNNING)
        Inspecting The Lift Arm By-Pass Control
    ARM REST SENSOR
        Removal And Installation
    WHEEL SPEED SENSOR
        Removal and Installation (Front Axle)
        Removal and Installation (Rear Axle)
    WHEEL POSITION SENSOR
        Removal and Installation (Front Axle)
        Removal and Installation (Rear Axle)
    CALIBRATION
        Travel Pedal
        Brake Pedal
        Calibration for the brake pedal is complete.
        Pump
        Wheel Alignment Calibration
    SERVICE PC (LAPTOP COMPUTER)
        Connecting The Service PC To Remote Start Tool
    TRAVEL DIRECTION CONTROL LEVER
        Removal And Installation
        
ENGINE SERVICE
    TROUBLESHOOTING
        Chart
    ENGINE SPEED CONTROL
        Removal And Installation
    MUFFLER
        Removal and Installation
    AIR CLEANER
        Removal and Installation
    RADIATOR
        Removal And Installation
    COOLING FAN
        Removal And Installation
        Fan Motor Disassembly and Assembly
    ENGINE COMPONENTS AND TESTING
        Compression Checking
        Glow Plugs Checking
        Glow Plugs Removal And Installation
        Fuel Shut-Off Solenoid Checking
        Fuel Shut-Off Solenoid Adjusting
        Fuel Shut-Off Solenoid Removal And Installation
        Checking
        Fuel Injection Pump Removal And Installation
        Timing The Injection Pump
        Fuel Injector Removal And Installation
        Fuel Injector Checking
        Fuel Injector Disassembly
        Fuel Injector Assembly
        Valve Clearance Adjustment
        Rocker Arm And Shaft Checking
        Valve Timing Checking
    ENGINE
        Removal And Installation
        Engine Mount Replacement
    FLYWHEEL AND HOUSING
        Flywheel Removal And Installation
        Ring Gear Removal And Installation
        Housing Removal And Installation
    RPM SENSOR
        Adjustment
    RECONDITIONING THE ENGINE
        Cylinder Head Removal And Installation
        Cylinder Head Disassembly And Assembly
        Cylinder Head Servicing
        Cylinder Head Top Clearance
        Checking The Valve Guide
        Reconditioning The Valve And Valve Seat
        Valve Spring
        Rocker Arm And Shaft Checking
        Timing Gearcase Cover Removal And Installation
        Idler Gear And Camshaft Removal And Installation
        Servicing The Camshaft
        Servicing The Idler Gear And Shaft
        Timing Gears Checking Backlash
        Fuel Camshaft Removal And Installation
        Fuel Camshaft Governor
        Crankshaft Gear Removal And Installation
        Oil Pump Removal And Installation
        Oil Pump Service
        Checking Engine Oil Pressure
        Relief Valve
        Piston And Connecting Rod Removal And Installation
        Servicing The Piston And Connecting Rod
        Connecting Rod Alignment
        Crankshaft And Bearings Removal And Installation
        Servicing The Crankshaft And Bearings
        Checking The Cylinder Bore
        Water Pump Disassembly And Assembly
        
HEATING, VENTILATION, AIR CONDITIONING
    AIR CONDITIONING SYSTEM FLOW
        Principals
        Chart
    COMPONENTS
        Identification
    SAFETY
        Safety Equipment
    REGULAR MAINTENANCE
        Filter Elements Removal And Installation
        Cleaning The Condenser
    GENERAL AIR CONDITIONING SERVICE GUIDELINES
        Compressor Oil
        Compressor Oil Check
        Component Replacement And Refrigeration Leaks
    SYSTEM TROUBLESHOOTING
        Checking A/C Performance
        Gauge Pressure Related Troubleshooting
        Troubleshooting Tree
    TEMPERATURE/PRESSURE
        Chart
    AIR CONDITIONING SERVICE
        Chart
    SYSTEM CHARGING AND RECLAMATION
        Reclamation Procedure
        Charging Procedure With A Manifold Gauge Set
    COMPRESSOR
        Removal And Installation
        Compressor Clutch Disassembly
    CONDENSER
        Removal And Installation
    RECEIVER/DRIER
        Removal And Installation
        Pressure Switch Removal And Installation
        Pressure Relief Valve Removal And Installation
    EVAPORATOR/HEATER UNIT
        Removal And Installation
    THERMOSTAT
        Removal And Installation
    EXPANSION VALVE
        Removal And Installation
    HEATER/AC FAN
        Removal And Installation
    HEATER VALVE
        Removal And Installation
        Disassembly And Assembly
        
SPECIFICATIONS
    UTILITY WORK MACHINE SPECIFICATIONS
        Dimensional Specifications
        Performance
        Controls
        Engine
        Hydraulic System
        Electrical
        Drive System
        Capacities
        Tires
    ENGINE SPECIFICATIONS
        Fuel Injection Nozzles
        Fuel Injection Pump
        Cylinder Head
        Valves
        Valve Springs
        Valve Timing
        Rocker Arms
        Camshaft
        Tappet
        Cylinders
        Piston Rings
        Pistons
        Connecting Rod
        Oil Pump
        Crankshaft
        Timing Gear
        Thermostat
        Crankshaft Re-Grind Data
    TORQUE SPECIFICATIONS FOR BOLTS
        Torque For General SAE Bolts
        Torque For General Metric Bolts
        Torque For Kubota Metric Bolts
    HYDRAULIC CONNECTION SPECIFICATIONS
        O-ring Face Seal Connection
        Straight Thread O-ring Fitting
        Tubelines And Hoses
        Flare Fitting
        O-ring Flare Fitting
        Port Seal Fitting
        Quick-Lok™ Fitting
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
        Specifications
    CONVERSIONS
        Decimal And Millimeter Equivalents
        U.S. To Metric Conversion
        
SERVICE MANUAL REVISION
    Revision No: 5600 - 1
    Revision No: 5600 - 2
    Revision No: 5600 - 3
    Revision No: 5600 - 4
    Revision No: 5600 - 5
    Revision No: 5600 - 6
    Revision No: 5600 - 7
    Revision No: 5600 - 8
    
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