Bobcat Toolcat 5600 Utility Work Machine Workshop Repair Service Manual - 6904209

(S/N: A00211001 & Above - S/N: A00311001 & 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: A00211001 & Above
S/N: A00311001 & Above


TABLE OF CONTENTS :

SAFETY & MAINTENANCE 
HYDRAULIC SYSTEM 
HYDROSTATIC SYSTEM 
DRIVE SYSTEM 
MAINFRAME 
ELECTRICAL SYSTEM & ANALYSIS 
ENGINE SERVICE 
HEATING, VENTILATION, AIR CONDITIONING 
SPECIFICATIONS 
ALPHABETICAL INDEX 
SERVICE MANUAL REVISION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6904209 (2-10)
Total Pages : 745


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 !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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CONTENTS
FOREWORD
    FOREWORD
    SAFETY INSTRUCTIONS
    FIRE PREVENTION
        Maintenance
        Operation
        Electrical
        Hydraulic System
        Fueling
        Starting
        Spark Arrestor Exhaust System
        Welding And Grinding
        Fire Extinguishers
    SERIAL NUMBER LOCATIONS
        Utility Work Machine Serial Number
        Engine Serial Number
    DELIVERY REPORT
    TOOLCAT UTILITY WORK MACHINE IDENTIFICATION
    
SAFETY & MAINTENANCE
    LIFTING AND BLOCKING THE UTILITY WORK MACHINE
        Procedure For Jackstand Placement On The Axle
        Procedure For Jackstand Placement On The Frame
    LIFT ARM SUPPORT DEVICE
        Installing
        Removing
    CARGO BOX SUPPORT DEVICE
        Installing
        Removing
        Raising The Cargo Box When Engine Is Not Running
    OPERATOR CAB
        Description
    TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER
        Loading And Unloading
        Fastening
    TOWING THE UTILITY WORK MACHINE
        Procedure
    REMOTE START
        Procedure
    SERVICE SCHEDULE
        Chart
    AIR CLEANER SERVICE
        Replacing Filter Elements
    ENGINE COOLING SYSTEM
        Cleaning
        Checking
        Removing And Replacing Coolant
    FUEL SYSTEM
        Fuel Specifications
        Filling The Fuel Tank
        Fuel Filter
        Removing Air From The Fuel System
        Filling A Portable Fuel Container
    ENGINE LUBRICATION SYSTEM
        Checking And Adding Engine Oil
        Engine Oil Chart
        Removing And Replacing Oil And Filter
    HYDRAULIC / HYDROSTATIC SYSTEM
        Checking And Adding Fluid
        Hydraulic / Hydrostatic Fluid Chart
        Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters
        Removing And Replacing Hydraulic Fluid
        Breather Cap
    AXLE / DIFFERENTIAL (FRONT AND REAR)
        Checking And Adding Lubricant
        Removing And Replacing Lubricant
    BOB-TACH
        Inspection And Maintenance
    LUBRICATING THE UTILITY WORK MACHINE
        Lubrication Locations
    TIRE MAINTENANCE
        Wheel Nuts
        Rotating
        Mounting
    SPARK ARRESTOR MUFFLER
        Cleaning Procedure
    PIVOT PINS
        Inspection And Maintenance
    UTILITY WORK MACHINE STORAGE AND RETURN TO SERVICE
        Storage
        Return To Service
    STOPPING THE ENGINE AND LEAVING THE UTILITY WORK MACHINE
        Procedure
        Emergency Exit
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    HYDRAULIC SYSTEM INFORMATION
        Glossary Of Hydraulic / Hydrostatic Symbols
        Troubleshooting
    CYLINDER (LIFT)
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (TILT)
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (CARGO BOX)
        Testing (Left Side Cylinder)
        Testing (Right Side Cylinder)
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    MAIN RELIEF VALVE
        Description
        Auxiliary Main Relief Valve Testing
        Auxiliary Main Relief Valve Removal And Installation
        Lift, Tilt And Cargo Box Main Relief Valve Testing
        Lift, Tilt And Cargo Box Main Relief Valve Removal And Installation
    PORT RELIEF VALVES
        Description
        Lift Port Relief Valve Testing
        Tilt Port Relief Valve Testing
    HYDRAULIC CONTROL VALVE
        Description
        Removal And Installation
        Identification Chart
        Disassembly
        End Valve Section Disassembly And Assembly
        Lift Valve Section Disassembly And Assembly
        Tilt Valve Section Disassembly And Assembly
        Box Valve Section Disassembly And Assembly
        High Flow Valve Section Disassembly And Assembly
        Auxiliary Valve Section Disassembly And Assembly
        Assembly
    STEERING SELECTOR VALVE
        Description
        Removal And Installation
        Disassembly And Assembly
    PILOT MANIFOLD
        Description
        Removal And Installation
        Disassembly And Assembly
    LIFT ARM BYPASS CONTROL VALVE
        Description
        Testing
        Removal And Installation
        Disassembly And Assembly
    HYDRAULIC PUMP
        Description
        Auxiliary Section Testing
        Lift, Tilt And Cargo Box Section Testing
        Steering And Cooling Fan Section Testing
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
    POWER STEERING PUMP
        Description
        Removal And Installation
        Disassembly And Assembly
    HYDRAULIC / HYDROSTATIC FILTER
        Description
        Housing Removal And Installation
        Case Drain Housing Removal And Installation
    CONTROL JOYSTICK
        Description
        Handle Removal And Installation
        Removal And Installation
        Disassembly And Assembly
    HYDRAULIC FLUID RESERVOIR
        Description
        Removal And Installation
        Hydraulic Fluid Screen
    OIL COOLER
        Description
        Removal And Installation
    AUXILIARY HYDRAULIC COUPLER BLOCK
        Description
        Removal And Installation (Front)
        Removal And Installation (Rear)
        Disassembly And Assembly
    REMOTE HYDRAULICS DIVERTER VALVE
        Description
        Removal And Installation
        Disassembly And Assembly
    PTO HYDRAULIC MOTOR
        Description
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    REAR AUXILIARY DIVERTER VALVE
        Description
        Solenoid Testing
        Removal And Installation
        Disassembly And Assembly
        
HYDROSTATIC SYSTEM
    HYDROSTATIC SYSTEM INFORMATION
        Troubleshooting
        Description
    HYDROSTATIC DRIVE MOTOR
        Description
        Removal And Installation (Front Axle)
        Removal And Installation (Rear Axle)
        Parts Identification
        Disassembly
        Assembly
    CHARGE PRESSURE
        Description
        Testing
    HYDROSTATIC PUMP
        Description
        Removal And Installation
        Directional Control Valve Removal And Installation
        PWM Control Valve Removal And Installation
        Replenishing / High Pressure Relief Valve Removal And Installation
        Charge Relief Valve Removal And Installation
        Parts Identification (Left Half)
        Parts Identification (Right Half)
        Disassembly
        Assembly
        Hydrostatic Pump Start-Up
        Pump Neutral Adjustment
    DRIVE BELT
        Description
        Shield Removal And Installation
        Adjusting
        Belt Removal And Installation
        Tensioner Pulley Removal And Installation
        Tensioner Pulley Parts Identification
        Tensioner Pulley Disassembly
        Tensioner Pulley Assembly
        
DRIVE SYSTEM
    BRAKE
        Description
        Disassembly And Assembly (Front Axle)
        Disassembly And Assembly (Rear Axle)
    AXLE
        Description
        Front Axle Brush Guard Removal And Installation
        Front Axle Removal And Installation
        Rear Axle Removal And Installation
        Separate 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
        Join The Axle Housings
    AXLE HUB WITH AXLE SHAFT
        Description
        Removal And Installation (Without Wheel Position Sensor)
        Removal (With Wheel Position Sensor)
        Installation (With Wheel Position Sensor)
    AXLE HUB WITHOUT AXLE SHAFT
        Description
        Removal And Installation (Without Wheel Position Sensor)
        Removal (With Wheel Position Sensor)
        Installation (With Wheel Position Sensor)
        Disassembly
        Assembly
        Torque Check Procedure
    AXLE SHAFT
        Description
        Removal And Installation
    TIE ROD
        Description
        Removal And Installation (Front Axle)
        Removal And Installation (Rear Axle)
        Adjusting
        
MAINFRAME
    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
        Lower Cushion Removal And Installation
        Back Cushion 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
        Description
        Removal And Installation
        Lever And Wedge Disassembly And Assembly
    LIFT ARM
        Removal And Installation
    CARGO BOX
        Removal And Installation
    STEERING COLUMN
        Removal And Installation
    FUEL TANK
        Main Tank Removal And Installation
        Auxiliary Tank Removal And Installation
        Fuel Level Sender Removal And Installation
    DRIVE AND BRAKE PEDALS
        Description
        Removal And Installation
        Drive Pedal Disassembly And Assembly
    SHOCKS
        Removal And Installation
    TRAILING ARMS
        Description
        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
        Access Cover 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
    WINDOWS
        Front, Rear And Lower Door Removal And Installation
        Upper Door Removal And Installation
        
ELECTRICAL SYSTEM & ANALYSIS
    ELECTRICAL SCHEMATICS
    ELECTRICAL SYSTEM INFORMATION
        Glossary Of Electrical Symbols
        Description
        Troubleshooting
        Fuse And Relay Location / Identification
        Solenoid Testing
    BATTERY
        Removal And Installation
        Servicing
        Using A Booster Battery (Jump Starting)
    ALTERNATOR
        Belt Adjustment
        Charging System Inspection
        Alternator Voltage Testing
        Low Voltage Testing
        High Voltage Testing
        Removal And Installation
        Parts Identification
    STARTER
        Testing
        Removal And Installation
        Parts Identification
    INSTRUMENT PANELS
        Display Controller Panel
        Switch Panel
        Floor Console
        Center Console
        Display Controller Panel Removal And Installation
        Light Bulb Removal And Installation
    LIGHTS
        Front Removal And Installation
    BOBCAT CONTROLLER (DISPLAY)
        Description
        Connector Identification
        Removal And Installation
    BOBCAT CONTROLLER (DRIVE)
        Description
        Connector Identification
        Removal And Installation
    DIAGNOSTIC SERVICE CODES
        Description
        Service Codes List
    DISPLAY CONTROLLER PANEL SETUP
        Display Selection
        Passwords
        Password Entry (For Starting And Operating The Machine)
        Changing The Owner And Operator Password
        Password Lockout Feature
        Job Clock
        RPM
    TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)
        Description
        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 Bypass Control
    ARM REST SENSOR
        Description
        Removal And Installation
    SPEED SENSORS
        Description
        Removal And Installation (Front Axle)
        Removal And Installation (Rear Axle)
    WHEEL POSITION SENSORS
        Description
        Removal And Installation (Front Axle)
        Removal And Installation (Rear Axle)
    SERVICE PC (LAPTOP COMPUTER)
        Connecting Remote Start Tool
    CALIBRATION
        Description
        Drive Pedal Calibration
        Brake Pedal Calibration
        Hydrostatic Pump Calibration
        Wheel Alignment Calibration
    TRAVEL DIRECTION CONTROL LEVER
        Description
        Removal And Installation
    FLYWHEEL RPM SENSOR
        Description
        Adjusting
    ELECTRIC COOLING FAN
        Description
        Removal And Installation
        
ENGINE SERVICE
    ENGINE INFORMATION
        Description
        Engine Specifications-Kubota V2203-M-DI
        Engine Specifications-Kubota V2003-M-DI-T (Turbo)
        Engine Torque Values
        Troubleshooting
        Engine Removal And Installation
        Engine Mount Replacement
        Compression - Checking
    ENGINE SPEED CONTROL
        Removal And Installation
        Speed Control Cable Removal And Installation
    MUFFLER
        Removal And Installation
    AIR CLEANER
        Housing Removal And Installation
    ENGINE COOLING SYSTEM
        Radiator Removal And Installation
        Radiator Mount Removal And Installation
        Hydraulic Fan Removal And Installation
        Hydraulic Fan Disassembly And Assembly
        Water Pump Removal And Installation
        Water Pump Disassembly And Assembly
        Thermostat Housing Removal And Installation
    LUBRICATION SYSTEM
        Oil Pan Removal And Installation
        Oil Pump Removal And Installation
        Oil Pump Inspection
        Engine Oil Pressure - Testing
    FUEL SYSTEM
        Fuel Camshaft Removal And Installation
        Fuel Camshaft Governor Disassembly And Assembly
        Fuel Shutoff Solenoid - Checking
        Fuel Shutoff Solenoid Removal And Installation
        Fuel Injection Pump Removal And Installation (Turbo)
        Fuel Injection Pump Removal And Installation (Non- Turbo)
        Injection Pump - Timing
        Fuel Injector Removal And Installation
        Fuel Injector Nozzle Pressure - Checking
        Nozzle Spray Condition
        Valve Seat Tightness
    CYLINDER HEAD
        Glow Plugs - Testing
        Glow Plugs Removal And Installation
        Valve Clearance Adjustment
        Valve Timing - Checking
        Cylinder Head Removal And Installation
        Cylinder Head Disassembly And Assembly
        Cylinder Head - Servicing
        Cylinder Head Top Clearance
        Valve Guide - Checking
        Reconditioning The Valve And Valve Seat
        Valve Spring
        Valve Tappets
        Rocker Arm And Shaft - Checking
    CRANKSHAFT AND PISTONS
        Piston And Connecting Rod Removal And Installation
        Piston And Connecting Rod - Servicing
        Cylinder Bore - Checking
        Connecting Rod Alignment
        Crankshaft Gear Removal And Installation
        Crankshaft And Bearings Removal And Installation
        Crankshaft And Bearings - Servicing
    CAMSHAFT AND TIMING GEARS
        Timing Gearcase Cover Removal And Installation
        Timing Gears Backlash - Checking
        Idler Gear And Camshaft Removal And Installation
        Camshaft - Servicing
        Idler Gear And Shaft - Servicing
    TURBOCHARGER
        Description
        Testing
        Removal And Installation
    FLYWHEEL AND HOUSING
        Flywheel Removal And Installation
        Ring Gear Removal And Installation
        Housing Removal And Installation
        
HEATING, VENTILATION, AIR CONDITIONING
    AIR CONDITIONING SYSTEM FLOW
        Description
        Chart
        Components
        Safety Equipment
    REGULAR MAINTENANCE
        Filter Elements Removal And Installation
        Compressor Drive Belt Inspection
        Condenser
        Air Conditioning Service Chart
        A/C Evaporator Coil
    TROUBLESHOOTING
        Blower Motor Does Not Operate
        Blower Motor Operates Normally But Air Flow Is Insufficient
        Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
        The Compressor Does Not Operate At All Or Operates Improperly
        Gauge Pressure Related Troubleshooting
        Temperature / Pressure Chart
        Poor A/C Performance
        HVAC Repair And Leaks
        Electrical System
        Engine Coolant Bypassing The Heater Valve
        Heater Valve Not Opening Or Closing
    SYSTEM CHARGING AND RECLAMATION
        Refrigerant Identification
        Reclamation And Charging With Recovery / Charging Unit
        Charging With A Manifold Gauge Set
    COMPRESSOR
        Belt Adjusting
        Removal And Installation
        Oil
        Oil Check
        Clutch Disassembly And Assembly
    CONDENSER
        Removal And Installation
    RECEIVER / DRIER
        Receiver / Drier Removal And Installation
        Pressure Relief Valve Removal And Installation
        Pressure Switch Removal And Installation
    EVAPORATOR / HEATER UNIT
        Removal And Installation
    THERMOSTAT
        Removal And Installation
    EXPANSION VALVE
        Removal And Installation
    EVAPORATOR COIL
        Removal And Installation
    HEATER COIL
        Removal And Installation With A/C
    BLOWER FAN
        Removal And Installation
    HEATER VALVE
        Removal And Installation
        Disassembly And Assembly
        
SPECIFICATIONS
    TOOLCAT 5600 UTILITY WORK MACHINE SPECIFICATIONS
        Dimensions
        Performance
        Controls
        Engine
        Hydraulic System
        Electrical
        Power Take-Off (PTO) System (Option)
        Drive System
        Capacities
        Tires
    TORQUE SPECIFICATIONS FOR BOLTS
        Torque For General SAE Bolts
        Torque For General 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 Equivalent Chart
        U.S. To Metric Conversion Chart
        
ALPHABETICAL INDEX

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
    
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