Bobcat Toolcat 5610 Utility Work Machine Workshop Repair Service Manual - 6990054

(S/N: APFB11001 & Above) 
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This workshop repair service manual PDF download for the Toolcat™ 5610 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™ 5610 
S/N: APFB11001 & 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 : 6990054 (3-11)
Total Pages : 799


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
CONTENTS
FOREWORD
    FOREWORD
    SAFETY INSTRUCTIONS
        Use Safety Rules
        Safety Rules For Power Take-Off (PTO) Driven Implements
    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
    UTILITY WORK MACHINE IDENTIFICATION
    
SAFETY & MAINTENANCE
    LIFTING AND BLOCKING THE UTILITY WORK MACHINE
        Procedure For Jackstand Placement On The Control Arms
        Procedure For Jackstand Placement On The Frame
    LIFT ARM SUPPORT DEVICE
        Installing
        Removing
    OPERATOR CAB
        Description
    TRANSPORTING THE UTILITY WORK MACHINE ON A TRAILER
        Loading And Unloading
        Fastening
    TOWING THE UTILITY WORK MACHINE
        Procedure
    REMOTE START TOOL KIT-MEL1563
        Remote Start Tool - MEL1563
        Service Tool Harness Control - MEL1565
        Service Tool Harness Communicator - MEL1566
        Remote Start Procedure
    REMOTE START TOOL (SERVICE TOOL) KIT - 6689779
        Description
        Remote Start Tool (Service Tool) - 6689778
        Service Tool Harness - 6689747
        Computer Service Tool Harness - 6689746
        Remote Start Procedure
    SERVICE SCHEDULE
        Chart
    AIR CLEANER SERVICE
        Replacing Filter Elements
    ENGINE COOLING SYSTEM
        Checking Level
        Cooling System Service Access Position
        Cleaning
        Removing And Replacing Coolant
    FUEL SYSTEM
        Fuel Specifications
        Biodiesel Blend Fuel
        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 Fluid
        Hydraulic / Hydrostatic Fluid Chart
        Adding Fluid
        Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters
        Removing And Replacing Hydraulic Fluid
        Breather Cap
    TRANSAXLE (FRONT AND REAR)
        Checking And Adding Lubricant
        Removing And Replacing Lubricant
    BOB-TACH (HAND LEVER)
        Inspection And Maintenance
    BOB-TACH (POWER OPTION)
        Inspection And Maintenance
    LUBRICATING THE UTILITY WORK MACHINE
        Lubrication Locations
    TIRE MAINTENANCE
        Wheel Nuts
        Rotating
        Mounting
    SPARK ARRESTER 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 (When Equipped With Cab)
    SEAT BELT
        Inspection And Maintenance
        
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 (THREE-POINT LIFT)
        Testing
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    CYLINDER (STEERING)
        Testing (Rear)
        Testing (Front)
        Removal And Installation (Rear)
        Removal And Installation (Front)
        Parts Identification
        Disassembly And Assembly
    CYLINDER (BOB-TACH)
        Testing
        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 Three-Point Main Relief Valve Testing
        Lift, Tilt And Three-Point Main Relief Valve Removal And Installation
    PORT RELIEF VALVES
        Description
        Lift Port Relief Valve Testing (Base End)
        Lift Port Relief Valve Testing (Rod End)
        Tilt Port Relief Valve Testing
        Three-Point Port Relief Valve Testing (Base End)
    HYDRAULIC CONTROL VALVE
        Description
        Removal And Installation
        Identification Chart
        Disassembly
        End Valve Section Disassembly And Assembly
        Three-Point Valve Section Disassembly And Assembly
        Lift Valve Section Disassembly And Assembly
        Tilt Valve Section Disassembly And Assembly
        Mid Inlet / 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
        Parts Identification
        Disassembly And Assembly
    LIFT ARM (BYPASS)
        Description
        Testing
    HYDRAULIC PUMP
        Description
        Auxiliary Section Testing
        Lift, Tilt And Three-Point 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
    HYDRAULIC FLUID RESERVOIR
        Description
        Removal And Installation
        Hydraulic Fluid Screen
    OIL COOLER
        Description
        Removal And Installation
    AUXILIARY HYDRAULIC COUPLER BLOCK
        Description
        Removal And Installation
        Disassembly And Assembly
    REMOTE HYDRAULICS DIVERTER VALVE
        Description
        Removal And Installation
        Disassembly And Assembly
    POWER BOB-TACH BLOCK
        Description
        Removal And Installation
        Disassembly And Assembly
    PTO HYDRAULIC MOTOR
        Description
        Removal And Installation
        Parts Identification
        Disassembly
        Assembly
    DIVERTER VALVE (PTO)
        Description
        Solenoid Testing
        Removal And Installation
        Disassembly And Assembly
        
HYDROSTATIC SYSTEM
    HYDROSTATIC SYSTEM INFORMATION
        Troubleshooting
        Description
    HYDROSTATIC DRIVE MOTOR
        Description
        Removal And Installation (Front)
        Removal And Installation (Rear)
        Parts Identification
        Disassembly
        Assembly
    CHARGE PRESSURE
        Description
        Testing
    HYDROSTATIC PUMP
        Description
        Removal And Installation
        Control Module Removal And Installation
        Replenishing / High Pressure Relief Valve Removal And Installation
        Charge Relief Valve Removal And Installation
        Parts Identification
        Disassembly And Assembly
        Mechanical Neutral Adjustment
        Hydraulic Controller Neutral Adjustment
    DRIVE BELT
        Description
        Shield Removal And Installation
        Adjusting
        Belt Replacement
        Tensioner Pulley Removal And Installation
        Tensioner Pulley Disassembly
        
DRIVE SYSTEM
    BRAKE
        Description
        Disassembly And Assembly (Front Transaxle)
        Disassembly And Assembly (Rear Transaxle)
    TRANSAXLE
        Description
        Removal And Installation (Front)
        Removal And Installation (Rear)
        Brake Housing Disassembly And Assembly
        Primary Housing Disassembly And Assembly
    HUB
        Description
        Removal And Installation
    CV SHAFT
        Description
        Removal And Installation (Front)
        Removal And Installation (Rear)
        Inner Boot Removal And Installation
        Outer Boot Removal And Installation
        
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
        Arm Rest Bracket Removal And Installation
        Arm Rest 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 (HAND LEVER)
        Description
        Removal And Installation
        Lever And Wedge Disassembly And Assembly
    BOB-TACH (POWER)
        Description
        Removal And Installation
        Lever And Wedge Disassembly And Assembly
    LIFT ARM
        Removal And Installation
    REAR COVER
        Opening And Closing
        Removal And Installation
        Latch Removal And Installation
        Latch Adjusting
        Rubber Bumper Adjusting
    STEERING COLUMN
        Removal And Installation
    FUEL 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
    CONTROL ARMS
        Removal And Installation (Lower Arm)
        Removal And Installation (Upper Arm)
        Inspection
        Ball Joint Removal And Installation
    SPINDLE
        Removal And Installation
    TIE ROD
        Description
        Removal And Installation
        Toe Adjustment Procedure
    FLOOR CONSOLE
        Access Cover Removal And Installation (Side)
        Access Cover Removal And Installation (Top)
    CENTER CONSOLE
        Removal And Installation
    FENDER
        Removal And Installation (Front)
        Removal And Installation (Left Rear)
        Removal And Installation (Right Rear)
    WINDOWS
        Front, Rear And Lower Door Removal And Installation
        Upper Door Removal And Installation
    THREE-POINT HITCH
        Lift Rod Removal And Installation
        Top Link Removal And Installation
        Lower Link Removal And Installation
        Stabilizer Removal And Installation
        Rock Shaft Removal
        Rock Shaft Installation
        
ELECTRICAL SYSTEM & ANALYSIS
    ELECTRICAL SCHEMATICS
    ELECTRICAL SYSTEM INFORMATION
        Glossary Of Electrical Symbols
        Cab Harness Connectors
        Mainframe / Engine Harness Connectors
        Description
        Troubleshooting
        Fuse And Relay Location - Cab Panel
        Fuse And Relay Location - Frame Panel
        Solenoid Testing
    BATTERY
        Removal And Installation
        Servicing
        Using A Booster Battery (Jump Starting)
    ALTERNATOR
        Belt Adjustment
        Belt Replacement
        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
    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
    CONTROL PANEL SETUP
        Enter Setup
        Two-Speed
        High Flow
        Horsepower Management
        Tire Size
        Save Setup
        Exit Setup
    PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START)
        Password Description
        Changing The Owner And Operator Passwords
        Password Lockout Feature
    TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)
        Description
        Inspecting The TICS
        Maintaining The TICS
        Lift Arm Bypass Procedure
        Inspecting
    ARM REST SENSOR
        Description
        Removal And Installation
    SPEED SENSOR (FRONT TRANSAXLE)
        Description
        Removal And Installation
    SPEED SENSOR (PTO MOTOR)
        Description
        Removal
        Installation
    WHEEL POSITION SENSORS
        Description
        Removal And Installation (Front)
        Removal And Installation (Rear)
        Adjusting (In The Machine)
        Adjusting (Out Of The Machine)
    SERVICE PC (LAPTOP COMPUTER)
        Connecting Remote Start Tool
        Connecting Remote Start Tool (Service Tool)
    CALIBRATION
        Description
        Throttle Position Sensor Calibration
        Drive System Calibration
        Brake Pedal Calibration
        Travel Pedal Calibration
    TRAVEL DIRECTION CONTROL LEVER
        Description
        Removal And Installation
    FLYWHEEL RPM SENSOR
        Description
        Adjusting
    ELECTRIC COOLING FAN
        Description
        Removal And Installation
    MAINTENANCE CLOCK
        Description
        Setup
        Reset
    BACK-UP ALARM SYSTEM
        Description
        Inspecting
        
ENGINE SERVICE
    ENGINE INFORMATION
        Description
        Specifications
        Torque Values
        Troubleshooting
        Engine Removal And Installation
        Engine Mount Replacement
        Compression - Checking
    ENGINE SPEED CONTROL
        Removal And Installation (Position Sensing)
        Removal And Installation (Non Position Sensing)
        Speed Control Cable Removal And Installation
    MUFFLER
        Removal And Installation
    AIR CLEANER
        Housing Removal And Installation
    ENGINE COOLING SYSTEM
        Cooling System Service Access Position
        Radiator 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
        Thermostat - Checking
    LUBRICATION SYSTEM
        Oil Pan Removal And Installation
        Oil Pump Removal And Installation
        Front Cover / Oil Pump Oil Seal Removal And Installation
        Relief Valve - Testing
        Oil Pump Inspection
        Oil Filter Cooler Removal And Installation
        Engine Oil Pressure - Testing
    FUEL SYSTEM
        Fuel Shutoff Solenoid - Checking
        Fuel Shutoff Solenoid Removal And Installation
        Fuel Injection Pump - Checking
        Fuel Injection Pump Assembly Removal And Installation
        Governor Housing Disassembly And Assembly
        Governor Disassembly And Assembly
        Fuel Camshaft Removal And Installation
        Fuel Injection Pump Removal And Installation
        Fuel 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
        Valve Guide Removal And Installation
        Reconditioning The Valve And Valve Seat
        Valve Spring
        Valve Tappets
        Rocker Arm And Shaft - Checking
        Bridge Arm And Bridge Arm Shaft - Checking
        Bridge Arm Shaft Removal And Installation
        Push Rod Alignment - 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
        Timing Gearcase Cover 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
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM
        Description
        Testing
        Removal And Installation
        Disassembly And Assembly
        
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 Adjustment
        Belt Replacement
        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
    (5610) UTILITY WORK MACHINE SPECIFICATIONS
        Dimensions (With 27 Inch Tires & Without Three-Point Hitch Option)
        Dimensions (With 27 Inch Tires & With Three-Point Hitch Option)
        Dimensions (With 29 Inch Tires & Without Three-Point Hitch Option)
        Dimensions (With 29 Inch Tires & With Three-Point Hitch Option)
        Performance
        Controls
        Engine
        Hydraulic System
        Electrical
        Power Take-Off (PTO) System
        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: 5610 - 1
    Revision No: 5610 - 2
    
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