Bobcat Toolcat 5600 AHG811001 & Up 6990860 (10-18) (Preview)
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 AND 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 – 7217666
Description
Remote Start Tool (Service Tool) – 7022042
Service Tool Harness – 6689747
Computer Service Tool Harness – 6689746
Remote Start Procedure
SERVICE SCHEDULE
Maintenance Intervals
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
TRANSAXLE (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
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
VALVE (MAIN RELIEF)
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
VALVE (PORT RELIEF)
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 (WITHOUT TRACTION CONTROL)
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
PILOT MANIFOLD (WITH TRACTION CONTROL)
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
Description
Handle Removal And Installation
HYDRAULIC FLUID RESERVOIR
Description
Removal And Installation
Hydraulic Fluid Screen
OIL COOLER / RADIATOR
Description
Removal And Installation
AUXILIARY HYDRAULIC COUPLER BLOCK
Description
Removal And Installation
Disassembly And Assembly (FFI/FI)
Disassembly And Assembly (FFH/FH)
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
Exhaust Tube Removal And Installation
Shield Removal And Installation
Belt 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
Armrest Bracket Removal And Installation
Armrest Removal And Installation
PASSENGER SEAT
Removal And Installation
Seat Belt Removal And Installation
Seat Pan Removal And Installation
Armrest 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
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
HEADLINER
Removal And Installation
ELECTRICAL SYSTEM AND ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Cab Harness Connectors
Mainframe Harness Connectors
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
Radio
LIGHTS
Front Removal And Installation
BOBCAT CONTROLLER (DISPLAY)
Description
Connector Identification
Removal And Installation
BOBCAT CONTROLLER (DRIVE)
Description
Connector Identification
Removal And Installation
ENGINE CONTROL UNIT (ECU)
Description
Cleaning
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 (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
ARMREST SENSOR
Description
Removal And Installation
SPEED SENSORS
Description
Removal And Installation (Front Transaxle)
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
ELECTRIC COOLING FAN
Description
Removal And Installation
MAINTENANCE CLOCK
Description
Setup
Reset
BACK-UP ALARM SYSTEM
Description
Inspecting
FRONT HORN
Description
Removal And Installation
Troubleshooting
TRACTION CONTROL
Description
Operation
Removal And Installation
ELECTRICAL / HYDRAULIC CONTROLS
Description
Identification Chart ACD Group 0
Identification Chart ACD Group 1
Identification Chart ACD Group 2
Identification Chart ACD Group 3
ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Sensor Location
Torque Values
Troubleshooting
Engine Removal And Installation
Engine Mount Replacement
Compression – Testing
Injector Signal – Testing
Injector Signal – Testing (In-Line)
ENGINE SPEED CONTROL
Removal And Installation
Disassembly And Assembly
DIESEL OXIDATION CATALYST (DOC)
Removal And Installation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
Radiator / Oil Cooler Removal And Installation
Hydraulic Fan Description
Hydraulic Fan Removal And Installation
Hydraulic Fan Disassembly And Assembly
Water Pump Removal And Installation
Thermostat Housing Removal And Installation
Testing The Thermostat
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
Description
High Pressure Pump Removal And Installation
Fuel Temperature Sensor Removal And Installation
Fuel Cooler Removal And Installation
Fuel Cooler Bypass Valve Removal And Installation
Fuel Recirculation Valve Removal And Installation
Fuel Rail Assembly Removal And Installation
Fuel Injector Removal And Installation
Removing Air From The Fuel System
CYLINDER HEAD
Glow Plugs Testing
Glow Plugs Removal And Installation
Valve Clearance Adjustment
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
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
Engine Component Class
CAMSHAFT
Removal And Installation
Inspecting
GEARCASE
Gearcase Cover Removal And Installation
Gear Backlash
Gear Timing
Idle Gear Removal And Installation
TURBOCHARGER
Description
Removal And Installation
Inspection
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Description
Removal And Installation
Disassembly And Assembly
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW
Description
A/C System Diagram
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
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
Description
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
(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
TECHNICAL SERVICE GUIDE SPECIFICATIONS
Engine
Engine Torques
Cooling System
Loader Torques
Hydraulic / Hydrostatic System
Fuel Consumption
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
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