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Bobcat 5600 Toolcat SN 520511001 & Above Service Manual 6901892
File Format: PDF
Size: 16.34 MB
No. of pages: 602
Delivery Method: Instant Download Access your file immediately after purchase.
Table of Contents:
- 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
File Data
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