Bobcat 5600 Toolcat SN A0W111001 & Above Service Manual 6904792enUS (08-16) (P)

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Table of Contents:
- MAINTENANCE SAFETY
- CONTENTS
- FOREWORD
- FOREWORD
- SAFETY INSTRUCTIONS
- FIRE PREVENTION
- Maintenance
- Operation
- Electrical
- Hydraulic System
- Fueling
- Starting
- Spark Arrester 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
- 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 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
- 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
- Alternate Fill Procedure
- Removing And Replacing Hydraulic / Hydrostatic And Case Drain Filters
- Removing And Replacing Hydraulic Fluid
- Breather Cap
- TRANS AXLE (FRONT AND REAR)
- Checking And Adding Lubricant
- Removing And Replacing Lubricant
- BOB-TACH (HAND LEVER)
- Inspection And Maintenance
- BOB-TACH (POWER)
- 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 (CARGO BOX)
- Testing
- Removal And Installation (Left Side)
- Removal And Installation (Right Side)
- 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 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 (Base End)
- Lift Port Relief Valve Testing (Rod End)
- Tilt Port Relief Valve Testing
- HYDRAULIC CONTROL VALVE
- Description
- Removal And Installation
- Identification Chart
- Disassembly
- End Valve Section Disassembly And Assembly
- Box 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 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 S/N A94Y11001- A94Y12003, S/ N A94Y12005 - A94Y12034
- Description
- Handle Removal And Installation
- CONTROL JOYSTICK S/N A94Y12004, S/N A94Y12035 & ABOVE
- 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
- DIVERTER VALVE (REAR AUXILIARY)
- Description
- Solenoid Testing
- Removal And Installation
- Disassembly And Assembly
- HYDROSTATIC SYSTEM
- HYDROSTATIC SYSTEM INFORMATION
- Troubleshooting
- Description
- HYDROSTATIC 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 Parts Identification
- Tensioner Pulley Disassembly
- Tensioner Pulley Assembly
- DRIVE SYSTEM
- BRAKE
- Description
- Disassembly And Assembly (Front Trans Axle)
- Disassembly And Assembly (Rear Trans Axle)
- TRANS AXLE
- 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
- CARGO BOX
- Removal And Installation
- 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 S/N A94Y11001 - A94Y12003, S/N A94Y12005 - A94Y12034
- Removal And Installation
- CENTER CONSOLE S/N A94Y12004, S/N A94Y12035 & ABOVE
- 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
- 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 (With Early Model Joystick)
- Center Console (With Later Model Joystick)
- Display Controller Panel Removal And Installation
- Light Bulb Removal And Installation (S/N A0W111001 - A0W111722)
- Light Bulb Removal And Installation (S/N A0W111723 & Above)
- 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 Screen Selection
- Two-Speed
- High Flow
- Horsepower Management
- Tire Size
- Save Setup
- Exit Setup
- Password Description
- Password Entry (For Starting And Operating The Machine)
- 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
- Testing The Lift Arm Bypass Procedure
- ARM REST SENSOR
- Description
- Removal And Installation
- SPEED SENSORS
- Description
- Removal And Installation (Front Trans Axle)
- 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
- 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
- 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
- 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 AND AIR CONDITIONING (HVAC)
- 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 (S/N A0W111001 - A0W111373)
- Removal And Installation
- Disassembly And Assembly
- HEATER VALVE (S/N A0W111374 & ABOVE)
- Removal And Installation
- Disassembly And Assembly
- SPECIFICATIONS
- (5600) UTILITY WORK MACHINE SPECIFICATIONS
- Dimensions (With 27 Inch Tires)
- Dimensions (With 29 Inch Tires)
- Performance
- Controls
- Engine
- Hydraulic System
- Electrical
- 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
- SERVICE TOOLS REQUIRED
- Remote Start Tools
- Hydraulic Tools
- Mainframe And Drive Tools
- Electrical Tools
- Engine Tools
- HVAC Tools
- ALPHABETICAL INDEX