Bobcat UW56 B4RC11001 & Up 7440683 (Preview)
MAINTENANCE SAFETY WARNINGS
MAINTENANCE SAFETY WARNINGS
CONTENTS
FOREWORD
FOREWORD
General Inspection
SAFETY INSTRUCTIONS
Call Before You Dig
Silica Dust Exposure
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrester Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATION
Machine Serial Number
Engine Serial Number
DELIVERY REPORT
UTILITY WORK MACHINE IDENTIFICATION
Front View
Rear View
SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE MACHINE
Procedure For Jackstand Placement On The Control Arms
Procedure For Jackstand Placement On The Frame
LIFT ARM SUPPORT
Installing The Lift Arm Support
Removing The Lift Arm Support
CARGO BOX SUPPORT
Installing Cargo Box Support
Removing Cargo Box Support
Raising The Cargo Box When Engine Is Not Running
OPERATOR CAB
Operator Cab Description
Level Ⅰ
TRANSPORTING THE MACHINE ON A TRAILER
Loading And Unloading
Fastening
TOWING THE MACHINE
Towing The Machine Procedure
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666
Remote Start Tool (Service Tool) Kit – 7217666 Description
Remote Start Tool (Service Tool) – 7022042
Service Tool Harness – 6689747
Computer Service Tool Harness – 6689746
MAINTENANCE INTERVALS
Service Schedule
AIR CLEANER SERVICE
Replacing Filter Elements
Outer Filter
Inner Filter
ENGINE COOLING SYSTEM
Checking Level
Propylene Glycol
Cleaning The Engine Cooling System
Removing And Replacing Coolant
FUEL SYSTEM
Fuel Specifications
U.S. Standard (ASTM D975)
E.U. Standard (EN590)
Biodiesel Blend Fuel
Filling The Fuel Tank
Fuel Filter
Removing Water
Replacing Fuel Pre-Filter
Replacing The Element
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 Hydraulic / Hydrostatic Fluid
Hydraulic Fluid Chart
Adding Fluid
Alternate Fill Procedure
Removing And Replacing Hydraulic / Hydrostatic Filter 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)
Inspecting And Maintaining Hand-Lever Bob-Tach
BOB-TACH (POWER)
Inspecting And Maintaining Power Bob-Tach
MACHINE LUBRICATION
Lubrication Locations
TIRE MAINTENANCE
Wheel Nuts
Rotating Tires
Mounting Tires
PIVOT PINS
Inspecting And Maintaining The Pivot Pins
MACHINE STORAGE AND RETURN TO SERVICE
Extended Storage Procedure
Returning The Machine To Service
STOPPING THE ENGINE AND LEAVING THE MACHINE
Stopping The Engine And Leaving The Machine
Emergency Exit
SEAT BELT
Inspecting And Maintaining The Seat Belt
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Flow Lines and Connections
Basic and Miscellaneous Symbols
Cylinder
Pump
Motor
Control Mechanisms
Non-Return Valve, Shuttle Valve
Directional Control Valve
Pressure Control Valve
Flow Control Valve
Miscellaneous
Troubleshooting The Hydraulic System
LIFT CYLINDER
Testing Lift Cylinder
Removing And Installing Lift Cylinder
Lift Cylinder Parts Identification
Disassembling Lift Cylinders
Assembling Lift Cylinder
TILT CYLINDER
Testing Tilt Cylinder
Removing And Installing Tilt Cylinder
Tilt Cylinder Parts Identification
Disassembling Tilt Cylinder
Assembling Tilt Cylinder
CARGO BOX CYLINDER
Testing Cargo Box Cylinder
Removing And Installing Cargo Box Cylinder (Left Side)
Removing And Installing Cargo Box Cylinder (Right Side)
Cargo Box Cylinder Parts Identification
Disassembling Cargo Box Cylinder
Assembling Cargo Box Cylinder
STEERING CYLINDER
Testing Rear Steering Cylinder
Testing Front Steering Cylinder
Removing And Installing Rear Steering Cylinder
Removing And Installing Front Steering Cylinder
Steering Cylinder Parts Identification
Disassembling And Assembling Steering Cylinder
BOB-TACH CYLINDER
Testing Bob-Tach Cylinder
Removing And Installing Bob-tach Cylinder
Bob-tach Cylinder Parts Identification
Disassembling Bob-tach Cylinder
Assembling Bob-Tach Cylinder
MAIN RELIEF VALVE
Main Relief Valve Description
Testing Auxiliary Main Relief Valve
Removing And Installing Auxiliary Main Relief Valve
Testing Lift, Tilt, And Cargo Box Main Relief Valve
Removing And Installing Lift, Tilt, And Cargo Box Main Relief Valve
PORT RELIEF VALVE
Port Relief Valve Description
Testing Base End Lift Port Relief Valve
Testing Rod End Lift Port Relief Valve
Testing Tilt Port Relief Valve
HYDRAULIC CONTROL VALVE
Hydraulic Control Valve Description
Removing And Installing Hydraulic Control Valve
Hydraulic Control Valve Identification Chart
Disassembling Hydraulic Control Valve
Disassembling And Assembling End Valve Section
Disassembling And Assembling Box Valve Section
Disassembling And Assembling Lift Valve Section
Disassembling And Assembling Tilt Valve Section
Disassembling And Assembling Mid Inlet / High Flow Valve Section
Disassembling And Assembling Auxiliary Valve Section
Assembling Hydraulic Control Valve
STEERING SELECTOR VALVE
Steering Selector Valve Description
Removing And Installing Steering Selector Valve
Disassembling And Assembling Steering Selector Valve
PILOT MANIFOLD (WITHOUT TRACTION CONTROL)
Pilot Manifold (Without Traction Control) Description
Removing And Installing Pilot Manifold (Without Traction Control)
Pilot Manifold (Without Traction Control) Parts Identification
Disassembling And Assembling Pilot Manifold (Without Traction Control)
PILOT MANIFOLD (WITH TRACTION CONTROL)
Pilot Manifold (With Traction Control) Description
Removing And Installing Pilot Manifold (With Traction Control)
Pilot Manifold (With Traction Control) Part Identification
Disassembling And Assembling Pilot Manifold (With Traction Control)
LIFT ARM (BYPASS)
Lift Arm (Bypass) Description
Testing Lift Arm (Bypass)
HYDRAULIC PUMP
Hydraulic Pump Description
Testing Auxiliary Section
Testing Lift, Tilt And Cargo Box Section
Testing Steering And Cooling Fan Section
Removing And Installing Hydraulic Pump
Hydraulic Pump Parts Identification
Disassembling And Assembling Hydraulic Pump
POWER STEERING PUMP
Power Steering Pump Description
Removing And Installing Power Steering Pump
Disassembling And Assembling Power Steering Pump
HYDRAULIC / HYDROSTATIC FILTER
Hydraulic / Hydrostatic Filter Description
Removing And Installing Hydraulic / Hydrostatic Filter Housing
Removing And Installing Case Drain Housing
CONTROL JOYSTICK
Control Joystick Description
Removing And Installing Handle
HYDRAULIC FLUID RESERVOIR
Hydraulic Fluid Reservoir Description
Removing And Installing Hydraulic Fluid Reservoir
Hydraulic Fluid Screen
OIL COOLER / RADIATOR
Oil Cooler / Radiator Description
Removing And Installing Oil Cooler / Radiator
AUXILIARY HYDRAULIC COUPLER BLOCK
Auxiliary Hydraulic Coupler Block Description
Removing And Installing Auxiliary Hydraulic Coupler Block
Disassembling And Assembling Coupler Block
REMOTE HYDRAULICS DIVERTER VALVE
Remote Hydraulics Diverter Valve Description
Removing And Installing Remote Hydraulics Diverter Valve
Disassembling And Assembling Remote Hydraulics Diverter Valve
POWER BOB-TACH BLOCK
Power Bob-Tach Block Description
Removing And Installing Power Bob-Tach Block
Disassembling And Assembling Power Bob-Tach Block
REAR AUXILIARY DIVERTER VALVE
Rear Auxiliary Diverter Valve Description
Testing Rear Auxiliary Diverter Valve Solenoid
Removing And Installing Rear Auxiliary Diverter Valve
Disassembling And Assembling Rear Auxiliary Diverter Valve
HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Hydrostatic System Information
Hydrostatic System Information Description
HYDROSTATIC MOTOR
Hydrostatic Motor Description
Removing And Installing Front Hydrostatic Motor
Removing And Installing Rear Hydrostatic Motor
Hydrostatic Motor Parts Identification
Disassembling Hydrostatic Motor
Assembling Hydrostatic Motor
CHARGE PRESSURE
Charge Pressure Description
Testing Charge Pressure
HYDROSTATIC PUMP
Hydrostatic Pump Description
Removing And Installing Hydrostatic Pump
Removing And Installing Control Module
Removing And Installing Replenishing / High Pressure Relief Valve
Removing And Installing Charge Relief Valve
Hydrostatic Pump Parts Identification
Disassembling And Assembling Hydrostatic Pump
Mechanical Neutral Adjustment
Hydraulic Controller Neutral Adjustment
DRIVE BELT
Drive Belt Description
Removing And Installing Shield
Removing And Installing Exhaust Tube
Adjusting The Drive Belt
Replacing The Drive Belt
Removing And Installing Tensioner Pulley
Disassembling Tensioner Pulley
DRIVE SYSTEM
BRAKE
Brake Description
Disassembling And Assembling Front Transaxle
Disassembling And Assembling Rear Transaxle
TRANSAXLE
Transaxle Description
Removing And Installing Front Transaxle
Removing And Installing Rear Transaxle
Disassembling And Assembling Brake Housing
Disassembling And Assembling Primary Housing
HUB
Hub Description
Removing And Installing Hub
CV SHAFT
CV Shaft Description
Removing And Installing Front CV Shaft
Removing And Installing Rear CV Shaft
Removing And Installing Inner Boot
Removing And Installing Outer Boot
MAINFRAME
OPERATOR CAB
Removing And Installing Operator Cab
OPERATOR SEAT
Removing And Installing The Operator Seat
Removing And Installing Seat Belt
Removing And Installing Seat Pan
Removing And Installing Slide Rail
Removing And Installing Armrest Bracket
Removing And Installing Armrest
PASSENGER SEAT
Removing And Installing The Passenger Seat
Removing And Installing Seat Belt
Removing And Installing Seat Pan
Removing And Installing Armrest
BOB-TACH (HAND LEVER)
Bob-Tach Hand Lever Description
Removing And Installing Bob-Tach Hand Lever
Disassembling And Assembling Lever And Wedge
BOB-TACH (POWER)
Bob-Tach Power Description
Removing And Installing Power Bob-Tach
Disassembling And Assembling Lever And Wedge
LIFT ARM
Removing And Installing Lift Arm
CARGO BOX
Removing And Installing Cargo Box
STEERING COLUMN
Removing And Installing Steering Column
FUEL TANK
Removing And Installing Fuel Tank
Removing And Installing Fuel Level Sender
DRIVE AND BRAKE PEDALS
Drive And Brake Pedals Description
Removing And Installing Drive And Brake Pedals
Disassembling And Assembling Drive Pedal
SHOCKS
Removing And Installing Shocks
CONTROL ARMS
Removing And Installing Lower Arm
Removing And Installing Upper Arm
Inspecting Control Arms
Removing And Installing Ball Joint
SPINDLE
Removing And Installing Spindle
TIE ROD
Tie Rod Description
Removing And Installing Tie Rod
Adjusting Toe
FLOOR CONSOLE
Removing And Installing Side Access Cover
Removing And Installing Top Access Cover
CENTER CONSOLE
Removing And Installing Center Console
FENDER
Removing And Installing Front Fender
Removing And Installing Left Rear Fender
Removing And Installing Right Rear Fender
WINDOWS
Removing And Installing Front And Rear Window
Removing Front And Rear Window
Installing Front And Rear Window
Removing And Installing Upper Door
HEADLINER
Removing And Installing Headliner
DASH
Removing And Installing Dash
ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Connections
Components
Senders And Sensors
Cab Harness Connectors
Mainframe Harness Connectors
Engine Alternator/Starter Harness Connectors
Engine Harness Connectors
Electrical System Information Description
Troubleshooting The Electrical System
Fuse And Relay Location – Cab Panel
Fuse And Relay Location – Frame Panel
Solenoid Testing
BATTERY
Removing And Installing The Battery
Battery Maintenance
Using A Booster Battery (Jump Starting)
ALTERNATOR
Adjusting The Alternator Belt
Replacing The Alternator Belt
Charging System Inspection
Alternator Voltage Testing
Low Voltage Testing
High Voltage Testing
Alternator Removal And Installation
STARTER
Testing The Starter
Starter Removal And Installation
Starter Parts Identification
ENGINE SPEED CONTROL
Engine Speed Control Description
Engine Speed Control Removal And Installation
OPERATOR CONTROLS AND INSTRUMENT PANELS
Operator Controls And Instrument Panel Overview
Center Console Overview
Standard Display
Jog Shuttle (Standard Display)
Left Control Panel Overview
Right Control Panel Overview
Center Control Panel Overview
Heating, Ventilation, And Air Conditioning (HVAC) Controls
Radio
Radio Identification
Adjusting Radio Settings
Operating Radio Timer
Operating The Radio Clock
LIGHTS
Front Lights Removal And Installation
BOBCAT HUB CONTROLLER
Bobcat Hub Controller Description
Bobcat Hub Controller Connector Identification
Removing And Installing Bobcat Hub Controller
BOBCAT CONTROLLERS (SFC PUMP AND SFC REAR)
Bobcat Controller (SFC Pump And SFC Rear) Description
Bobcat Controller (SFC Pump And SFC Rear) Removal And Installation
ENGINE CONTROL UNIT (ECU)
Engine Control Unit Description
Cleaning The Engine Control Unit
Engine Control Unit Removal And Installation
TOOLCAT INTERLOCK CONTROL SYSTEM (TICS)
Toolcat Interlock Control System (TICS) Description
Inspecting The TICS
Maintaining The TICS
Lift Arm Bypass Procedure
Inspecting The Toolcat Interlock Control System
ARMREST SENSOR
Armrest Sensor Description
Armrest Sensor Removal And Installation
SPEED SENSORS
Speed Sensor (Front Transaxle) Description
Speed Sensor (Front Transaxle) Removal And Installation
WHEEL POSITION SENSORS
Wheel Position Sensors Description
Wheel Position Sensors Removal And Installation (Front)
Wheel Position Sensors Removal And Installation (Rear)
Adjusting The Wheel Position Sensors (In The Machine)
Adjusting The Wheel Position Sensors (Out of The Machine)
SERVICE PC (LAPTOP COMPUTER)
Connecting Remote Start Tool (Service Tool)
CALIBRATION
Calibration Description
Throttle Position Sensor Calibration
Drive System Calibration
Brake Pedal Calibration
Travel Pedal Calibration
TRAVEL DIRECTION CONTROL LEVER
Travel Direction Control Lever Description
Travel Direction Control Lever Removal And Installation
ELECTRIC COOLING FAN
Electric Cooling Fan Description
Electric Cooling Fan Removal And Installation
MAINTENANCE CLOCK
Maintenance Clock Record A Service
Maintenance Clock View Service Codes
BACK-UP ALARM SYSTEM
Back-Up Alarm System Description
Inspecting The Back-Up Alarm System
FRONT HORN
Front Horn Description
Front Horn Removal And Installation
Front Horn Troubleshooting
TRACTION CONTROL
Traction Control Description
Traction Control Operation
Removing And Installing Traction Control Sensor
ELECTRICAL / HYDRAULIC CONTROLS
Electrical / Hydraulic Controls Description
Electrical / Hydraulic Controls Identification Chart ACD Group 0
Electrical / Hydraulic Controls Identification Chart ACD Group 1
Electrical / Hydraulic Controls Identification Chart ACD Group 2
Electrical / Hydraulic Controls Identification Chart ACD Group 3
ENGINE SERVICE
ENGINE INFORMATION
Engine Description
Engine Specifications
Valve Springs
Valves
Engine Valve Timing
Rocker Arms
Camshaft
Cylinder Bore
Piston Rings
Pistons
Connecting Rod
Oil Pump
Crankshaft
Timing Gear
Thermostat
Engine Sensor Location
Torque Values
Engine Troubleshooting
Removing And Installing Engine
Replacing Engine Mount
Testing Compression
Testing Injection Signal
Testing Oil Pressure (At Turbocharger Oil Inlet)
DIESEL OXIDATION CATALYST (DOC)
Removing And Installing Diesel Oxidation Catalyst (DOC)
AIR CLEANER
Removing And Installing Air Cleaner Housing
ENGINE COOLING SYSTEM
Removing And Installing Radiator / Oil Cooler
Hydraulic Fan Description
Removing And Installing Hydraulic Fan
Disassembling And Assembling Hydraulic Fan
Removing And Installing Water Pump
Removing And Installing Thermostat Housing
Testing The Thermostat
LUBRICATION SYSTEM
Lubrication System Description
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Relief Valve Description
Oil Pump Relief Valve Removal And Installation
Oil Cooler Removal And Installation
Oil Filter Head Removal And Installation
Oil Cooler Bypass Description
Oil Cooler Bypass Removal And Installation
FUEL SYSTEM
Fuel System Description
Fuel Filter Housing Removal And Installation
Fuel Lift Pump Removal And Installation
Fuel Lift Pump Filter Removal And Installation
Transfer Pump / High Pressure Pump Removal And Installation
Fuel Temperature Sensor Removal And Installation
Fuel Recirculation Valve (FRV) Removal And Installation
Fuel Pressure Relief Valve Removal And Installation
Fuel Rail Assembly Removal And Installation
Fuel Injector Removal And Installation
Injector Coding
CYLINDER HEAD
Glow Plug Testing
Removing And Installing Glow Plugs
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Valve Clearance Adjustment
Cylinder Head Inspection
Cylinder Head Top Clearance
Valve Step Height
Valve Stem Height
Valve Guide
Valve
Valve Spring
Rocker Arm Shaft Disassembly And Assembly
Rocker Arm Shaft Inspection
Push Rod Inspection
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod Inspection
Crankshaft Removal And Installation
Cylinder Block Inspection
Crankshaft Inspection
Connecting Rod Inspection
Engine Component Class
CAMSHAFT
Camshaft Removal And Installation
Inspecting Camshaft
GEARCASE
Gearcase Cover Removal And Installation
Gear Backlash
Gear Timing
Idle Gear Removal And Installation
Idle Gear Inspection
TURBOCHARGER
Turbocharger Description
Turbocharger Removal And Installation
Turbocharger Inspection
FLYWHEEL AND HOUSING
Removing And Installing Flywheel
Removing And Installing Ring Gear
Removing And Installing Housing
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Exhaust Gas Recirculation (EGR) System Description
Exhaust Gas Recirculation (EGR) System Removal And Installation
Exhaust Gas Recirculation (EGR) System Disassembly And Assembly
HVAC
AIR CONDITIONING SYSTEM FLOW
Air Conditioning System Flow Description
A/C System Diagram
Air Conditioning System Flow Components
Air Conditioning System Safety Equipment
REGULAR MAINTENANCE
Recirculating Air Filter
Compressor Drive Belt Inspection
Condenser
Air Conditioning Service Chart
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 Operates Improperly Or Not At All
Gauge Pressure Related Troubleshooting
Air Conditioning Temperature / Pressure Chart
Air Conditioning 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
Compressor Belt Adjustment
Compressor Belt Replacement
Compressor Removal And Installation
Oil
Oil Check
CONDENSER
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
Evaporator / Heater Unit Removal And Installation
THERMOSTAT
Thermostat Description
Thermostat Removal And Installation
EXPANSION VALVE
Expansion Valve Removal And Installation
EVAPORATOR COIL
Evaporator Coil Removal And Installation
HEATER COIL
Heater Coil Removal And Installation
BLOWER FAN
Blower Fan Removal And Installation
HEATER VALVE
Heater Valve Removal And Installation
Heater Valve Disassembly And Assembly
SPECIFICATIONS
MACHINE SPECIFICATIONS
Machine Dimensions
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tires
TECHNICAL SERVICE GUIDE SPECIFICATIONS
Technical Service Guide Specifications
Engine
Engine Torques
Cooling System
Loader Torques
Hydraulic / Hydrostatic System
Fuel Consumption
TORQUE SPECIFICATION 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
Tightening The Flare Fitting
O-ring Flare Fitting
Port Seal Fitting
Push To Connect Fittings
HYDRAULIC 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
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